XL 125 V1
IMPORTANT SAFETY NOTICE
indicates a strong possibility of severe personal injury or death if instructions sre not followed.
CAUTION: indicates a possibility of equipment damage if instructions are not followed.
NOTE: Gives helpful information.
Detailed descriptions of standard workshop procedures, safety principles and service operations are not included.
It is important to note that this manual contains some warnings and cautions against some specific service meth-
ods which could cause PERSONAL INJURY to service personnel or could darnage a vehicle or render it unsafe.
Please understand that those warnings could not cover all conceivable ways in which service, whether or not rec-
ommended by Honda, might be done or of the possibly hazardous consequences of each conceivable way, nor
could Honda investigate all such ways. Anyone using service procedures or tools, whether or not recommended
by Honda, must satisfy himself thoroughly that neither personal safety nor vehicle safety will be jeopardized by
the service methods or tools selected.
TYPE CODE
* Throughout this manual, the following addreviations are used to identify individual model.
GERMANY (TYPE II)
HOW TO USE THIS MANUAL
This service manual describes the service procedures
for the XL125V.
Follow the Maintenance Schedule (Section 3} racom-
mendations to ensure that the vehicle is in peak oper-
ating condition.
Performing the first schaduled maintenance is very
important. It compensates for the initial wear that
occurs during the break-in period.
Sections 1 and 3 apply to the whole motorcycle.
Section 2 illustrates procedures for removal/ installa-
tion of components that may be required to perform
service described in the following sections. Sections
4 through 20 describe parts of the motorcycle,
grouped according to location.
Find the section you want on this page, then turn to
the table of contents on the first page of the section.
Most sections start with an assembly or system illus-
tration, service information and troubleshooting for
the section.
The subsequent pages give detailed procedure.
If you don’t know the source of the trouble, go to sec-
tion 27 Troubleshooting.
ALL INFORMATION, iLLUSTRATIONS, DIREC-
TIONS AND SPECIFICATIONS INCLUDED IN THIS
PUBLICATION ARE BASED ON THE LATEST
PRODUCT INFORMATION AVAILABLE AT THE
TIME OF APPROVAL FOR PRINTING. HONDA
MOTOR CO., LTD. RESERVES THE RIGHT TO
MAKE CHANGES AT ANY TIME WITHOUT
NOTICE AND WITHOUT INCURRING ANY OBLIG-
ATION WHATEVER. NO PART OF THIS PUBLICA-
TION MAY BE REPRODUCED WITHOUT WRITTEN
PERMISSION. THIS MANUAL IS WRITTEN FOR
PERSONS WHO HAVE ACQUIRED BASIC KNOWL-
EDGE OF MAINTENANCE ON HONDA MOTORCY-
CLES, MOTOR SCOOTERS OR ATVS.
HONDA MOTOR CO., LTD.
SERVICE PUBLICATION OFFICE
ENGINE AND DRIVE TRAIN
Is
HASS
i
ELECTRICAL
WIRING DIAGRAM ) Gi 19 |
LUBRICATION SYSTEM | A |
CAO TCA Re TRANSMISSION/ 11
CRANKSHA
FRONT WHEEL/SUSPENSION/ 112
STEERING
-
CONTENTS
GENERAL INFORMATION
CRANE BODY PANELS/EXHAUST
SYSTE
MAINTENANCE
FUEL SYSTEM | 5 |
COOLING SYSTEM | 6 |
ENGINE REMOVAL/INSTALLATION
| CLUTCH/GEARSHIFT LINKAGE | 8 |
CYLINDER HEAD/VALVE
CYLINDER/PISTON
REAR WHEEL/SUSPENSION ke 3
BRAKE SYSTEM 14
CHARGING SYSTEM/ALTERNATOR a 5
IGNITION SYSTEM
ELECTRIC STARTER/ 17
STARTER CLUTCH
LIGHT/METER/SWITCHES & EI
TROUBLESHOOTING
| INDEX
_ Eg
_HI
SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required
pertaining to these symbols, it would be explained specifically in the text without the use of the symbols.
Replace the part(s} with new one(s) before assembly.
Use recommended engine oil, unless otherwise specified.
Use malybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio
of 1:1}.
Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent).
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI
#2 or aquivalent).
Example: Molykote® BR-2 plus manufactured by Dow corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI
#2 or equivalent).
Example: Molykote® G-n Paste manufactured by Dow corning, U.S.A.
Honda Moly 60 (U.S.A. only)
Rocot ASP manufactured by Rocol Limited, U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan
Use silicone grease.
Apply a locking agent. Use a middle strength locking agent unless otherwise specified.
Apply sealant.
Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified.
Use Fork or Suspension Fluid.
GENERAL SAFETY
SERVICE RULES
MODEL IDENTIFICATION
SPECIFICATIONS
TORQUE VALUES
GENERAL SAFETY
CARBON MONOXIDE
If the engine must be running to do some work, make
sure the area is well ventilated. Never run the engine in
an enclosed area.
Mm
The exhaust contains poisonous carbon monoxide gas
that may cause loss of consciousness and may lead to
death.
Run the engine in an open area or with an exhaust
avacuation system in an enclosed area.
GASOLINE
Work in a well ventilated area. Keep cigarettes, flames
or sparks away from the work area or where gasoline is
stored.
km _
Gasoline is extremely flammabie and is explosive under
certain conditions. KEEP OUT OF REACH OF CHILDREN.
HOT COMPONENTS
A WARNING
Engine and exhaust system parts become very hot and
remain hot for some time after the engine is run. Wear
insulated gloves or wait until the engine and exhaust
system have cooled before handling these parts.
1. GENERAL INFORMATION
TOOLS
LUBRICATION & SEAL POINTS
CABLE & HARNESS ROUTING
EMISSION CONTROL SYSTEMS
USED ENGINE OIL
Rm
Used engine oil may cause skin cancer if repeatedly left
in contact with the skin for prolonged periods.
Although this is unlikely unless you handle used oif on
a daily basis, it is still advisable to thoroughly wash
your hands with soap and water as soon as possible
after handling used oil. KEEP OUT OF REACH OF CHIL-
’ DREN.
BRAKE FLUID
CAUTION:
Spilling fluid on painted, plastic or rubber parts will
damage them. Place a clean shop towel over these
parts whenever the system is serviced. KEEP OUT OF
REACH OF CHILDREN.
BATTERY HYDROGEN & ELECTROLYTE
A WABNING
» The battery gives off explosive gases; keep sparks,
flames and cigarettes away. Provide adequate venti-
lation when charging or using the battery in an
enclosed space.
» The battery contains sulfuric acid (electrolyte).
Contact with skin or eyes may cause severe burns.
Wear protective clothing and a face shield.
— ff electrolyte gets on your skin, flush with water.
— Ff electrolyte gets in your ayes, flush with water for
at least 15 minutes and call a physician immediately.
* Electrolyte is poisonous.
— if swallowed, drink large quantities of water or milk
and follow with milk of magnesia or vegetable oil
and call a physician. KEEP OUT OF REACH OF
CHILDREN.
1-1
GENERAL INFORMATION
SERVICE RULES
1.
2:
3.
Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalents. Parts that do not meet
HONDA's design specifications may damage the motorcycle.
Use the special tools designed for this product.
Use only metric tools when servicing this motorcycle. Metric bolts, nuts and screws are not interchangeable with
English fasteners. The use of incorrect tools and fasteners may damage the motorcycle.
. Instal! new gaskets, O-rings, cotter pins, lock plates, etc. when reassembling.
. When tightening a series of bolts or nuts, begin with the larger-diameter of inner bolts first, and tighten to the speci-
fied torque diagonally, in incremental steps unless a particular sequence is specified.
. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
. After assembiy, check all parts for proper installation and operation.
. Route all electrical wires as show on pages 1- through 1- , Cable and Harness Routing.
GENERAL INFORMATION
ENGINE SERIAL NUMBER
The frame seria! number is stamped on the right side of The engine serial number is stamped on the left side
the steering head. of the crankcase.
CARBURETOR IDENTIFICATION NUMBER
The carburetor serial number is stamped on the left side
of the carburetor body as shawn.
GENERAL INFORMATION
SPECIFICATIONS
GENERAL
ITEM
DIMENSIONS Overall length
| Overall width
Overall height
Wheelbase
Seat height
Ground clearance
Dry weight
Curb weight
Maximum weight capacity
FRAME Frame type
Front suspension
Front wheal travel
Rear suspension
Rear wheel travel
Front tire size
Rear tire size
Front tire brand
Rear tire brand
Front brake
Rear brake
Caster angle
Trait length
Fuel tank capacity
Fuel tank reserve capacity
ENGINE Bore and stroke
Displacement
Compression ratio
Valve train
Intake valve
Exhaust valve
Lubrication systam
Oil pump type
Cooling system
Air filtration
Engine dry weight
opens
closes
opens
closes
SPECIFICATIONS
2,150 mm {84.6 in}
850 mm (33.5 in}
1,250 mm {49.2 in)
1,450 mm {57.1 in)
802 mm {31.6 in}
190 mm {7.5 in)
154 kg (339.5 lbs}
167 kg (368.2 Ibs)
180 kg (396.8 Ibs)
Doubte cradle
Telescopic fork
132 mm (5.2 in}
Swingarm
150 mm {5.9 in}
100/90-18 56P
130/80-17 65P
BRIDGESTONE, PIRELL!
BRIDGESTONE, PIRELLI
Hydraulic single dise
Hydraulic single disc
28°00’
97 mm (3.8 in}
17.5 liter (4.62 US gal, 3.85 Imp gal}
2.0 liter (0.53 US gal, 0.44 Imp gal)
42.0 x 45.0 mm (1.65 x 1.77 in)
125 cm {7.6 cu in)
11.851
Silent multi-link chain driven SOHC with rocker arms
6° BTDC
24° ABDC
31° BBDC
9° ATDC
Forced pressure {dry sump}
Trachoid
Liquid cooled
Viscous paper element
40.5 kg (89.29 Ibs)
GENERAL INFORMATION
es
CARBURETOR Carburetor Type CV (Constant Velocity) dual carburetor
Throttle bore 22 mm (0.9 in}
DRIVE TRAIN Clutch system Multi-plate, wet
Clutch operation system Mechanical type
Transmission Constant mesh, 5-speed
Primary reduction 3.722 (67/18)
Final reduction 3.142 (44/14)
Gear ratio 3.083 {37/12}
1,933 {29/15}
1.428 {30/21}
1.173 (27/23)
4.060 (25/25}
Gearshift pattern Left foot operated return system, 1-N-2-3-4-5
ELECTRICAL Ignition system Full transistor digital ignition
Starting system Electric starter motor
Charging system Triple phase output alterator
Regulator/rectifier SCR shorted/triple phase, full wave rectification
Lighting system Battery
GENERAL INFORMATION
Unit: mm {in
LUBRICATION SYSTEM =
ITEM STANDARD SERVICE LIMIT
Engine oil capacity at draining 1.1 liter (1.2 US qt, 1.0 Imp qt) —
at disassembly 1.5 liter (1.6 US qt, 1.3 Imp qt) , ——
at filter change 1.2 liter {1.3 US qt, 1.1 Imp gt) oe
Recommended engine oil HONDA 4-stroke oil or equivalent
motor oil matics
API service classification SE, SF or SG
Viscosity: SAE 10W - 40
Oil pump rotor Tip clearance 0.15 (0.006) 0.20 (0.008}
| Biren lbatate
Body clearance 0.15 — 0.21 (0.006 — 0.008) 0.25 (0.010}
Side clearance 0.03 - 0.11 (0.001 - 0.004) 0.15 (0.006}
FUEL SYSTEM
ITEM
SPECIFICATIONS
Carburetor identification number
VPU 2A
Main jet
#82
.| Slow jet
Jet needle number
Front
#88
C124
Rear
C12B
Pilot screw Initial/final opening
See page 5-18
Float level
13.7 mm (0.54 in)
Base carburetor (for synchronization)
Idle speed
PAIR control valve specified vacuum
Throttle grip free play
COOLING SYSTEM
ITEM
RN eeen ee ee Oe”
Front cylinder (#2}
1,500 + 100 min” (rpm}
280 mm Hg (11.02 in Hg}
2-6 mm (1/16 - 1/4 in}
SPECIFICATIONS
Coolant capacity Radiator and engine
Reserve tank
1.03 liter {1.08 US gt, 0.95 Imp qt}
0.24 liter (0.25 US gt, 0.21 imp at)
Radiator cap relief pressure
108 kpa (1.1 kgf/cm?, 16 psi}
Thermostat Begin to open
Fully open
Valve lift
Standard coolant concentration
81 - 84°C (178 — 183°F)
95°C (203°F)
4.5 mm (0.18 in} minimum
50% mixture with soft water
CLUTCH SYSTEM/GEARSHIFT LINKAGE
ITEM
- GENERAL INFORMATION
STANDARD
Unit: mm (in)
SERVICE LIMIT
Clutch lever free play
Clutch spring free length
Clutch disc thickness
Clutch plate warpage
10 — 20 (3/8 — 13/16)
42.1 (1.66)
2.92 - 3.08 (0.115 — 0.121)
2.92 — 3.08 (0.115 — 0.121)
41.2 (1.62)
2.6 (0.10)
2.6 (0.10}
25.959 — 25.980 (1.0220 — 1.0228)
0.30 (0.012)
25.94 (1.021}
Clutch outer guide f1.D. =| 20.010 - 20.035 (0.7878 - 0.7888) 20.05 (0.789)
Mainshaft 0.D. at clutch outer guide
CYLINDER HEAD/VALVE
ITEM
Cylinder compression
Cylinder head warpage
Valve clearance
Valve stem O.D.
Valve guide |.D.
Valve, valve
guide
Stem-to-guide clearance
Valve guide projection above
cylinder head
Valve seat width IN/EX
Valve spring free length
Camshaft Cam lobe height
Runout
Identification marks
Rocker arm I.D.
Rocker arm shaft O.D.
Rocker arm-to-rocker arm shaft clearance
19.959 — 19.980 (0.7858 — 0.7866)
STANDARD
1,304 kPa (13.3 kgf/cm’, 189 psi) at
500 min” {rpm}
| 19.94 (0.785)
Unit: mm {in)
SERVICE LIMIT
0.05 (0.002)
0.15 + 0.02 (0.006 + 0.001)
0.24 + 0.02 (0.009 + 0.001)
4.975 - 4.990 (0.1959 — 0.1965)
4.955 — 4.970 (0.1951 — 0.1957)
4.965 (0.1955}°
4.945 {0.1947}
5.000 — 5.012 (0.1969 ~ 0.1973)
5.03 (0,198)
5.000 - 5.012 (0.1969 — 0.1973)
5.03 (0.198)
0.010 — 0.037 (0.0004 — 0.0015}
0.030 - 0.057 {0.0012 — 0.0022)
12.10 {0.476}
0.065 (0.0026)
0.085 (0.0033)
12.10 {0.476}
0.90 - 1.10 (0.035 - 0.043)
1.5 {0.06)
38.00 (1.496)
38.00 (1.496)
28.8527 — 29.0927 (1.13593 — 1.14538)
28.8849 — 29.1249 (1.13720 - 1.14665}
| 36.5 (1.44)
36.5 (1.44}
28.82 (1.135)
28.85 (1.136}
0.030 (0.0012)
0.050 (0.0020)
Front “F"/Rear “R”
10.000 — 10.015 {0.3937 — 0.3943)
9.972 - 9.987 (0.3926 — 0.3932)
0.013 - 0.043 {0.0005 — 0.0017)
10.05 (0.396)
9.92 (0.391}
0.10 (0.004)
GENERAL INFORMATION
Unit: mm (in}
CYLINDER/PISTON
Cylinder I.D. 42.00 - 42.01 (1.654 - 1.654} 42.10 (1.657)
Out of round — 0.06 (0,002)
Taper — 0.06 (0.002)
Warpage — “| 0.05 (0.002)
Piston, Piston mark direction “IN” mark facing toward the intake side —
pistonrings | piston O.D. 41.97 - 41.99 (1.652 - 1.653) 41.90 (1.650)
Piston 0.D, measurement point 14.0 (0.55) from bottom of skirt “a —
Piston pin bore t.D. 13.002 — 13.008 (0.5119 — 0.5121} 13.04 (0.513}
Piston pin O.D. 12.994 — 13.000 (0.6116 - 0.5118) 12.98 (0.511}
Piston-to-piston pin clearance 0.002 -— 0.014 (0.0001 — 0.0006} 0.04 (0.002)
Piston ring-to-ring Top 0.015 — 0.05 (0.0006 — 0.002) 0.080 (0.0031)
groove clearance Second 0.015 - 0.05 (0.0006 - 0.002} 0.080 (0.0031)
Piston ring end gap Top 0.05 — 0.15 (0.002 - 0.006} 0.30 (0.012)
Second 0.20 - 0.35 (0.008 - 0.014) 0.50 (6.020)
Oil (side rail) | 0.10 - 0.60 (0.004 - 0.024)
Piston ring mark Top “R” mark
Second “RN*® mark
Cylinder-to-piston clearance
Connecting rod small end I.D.
Connecting rod-to-piston pin clearance
0.010 — 0.040 (0.0004 — 0.0016}
13.016 — 13.034 (0.5124 - 0.5131}
0.010 — 0.040 (0.0004 ~ 0.0016)
0.10 (0.004)
13.044 (0.5135)
0.06 (0.002)
1-8
GENERAL INFORMATION
CRANKCASE/TRANSMISSION/CRANKSHAFT Balog
Gear |.D.
Bushing O.D.
le a =
Bushing |.D.
18.000 - 18.018 (0.7087 - 0.7094) 18.04 (0.710)
Transmission
C2 20.000 — 20.021 (0.7874 - 0.7882) 20.04 (0.789)
C3 22.000 — 22.021 (0.8661 - 0.8670) 22.04 (0.868)
Gear-to-bushing M4, M5, 0.020 - 0.062 (0.0008 — 0.0024} 0.10 (0.004)
clearance C1,.62,.E3
Mainshaft 9.D.
Countershaft O.D.
19.959 - 19.980 (0.7858 - 0.7866) 19.94 (0.785)
17.966 — 17.984 (0.7073 — 0.7080) 17.95 (0.707)
C2 bushing 19.974 — 19.987 (0.7864 - 0.7869) 19.95 (0.785)
C3 bushing _| 21.959 - 21.980 (0.8645 - 0.8654)
:
Bushing-to-shaft
clearance
0.020 - 0.062 (0.0008 - 0.0024) 0.09 (0.004)
Shift fork 12.000 — 12.018 (0.4724 - 0.4731) 12.03 {0.474}
Claw thickness
Shift drum O.D. (at left side journal)
Connecting rod big end radial clearance
[Ruut SSO —=*d 08 00
GENERAL INFORMATION
FRONT WHEEL/SUSPENSION/STEERING
ITEM
STANDARD
Minimum tire tread depth
Cold tire pressure Driver only
200 kPa (2.0 kgf/cm?, 29 psi)
Driver and passenger
200 kPa (2.0 kgf/cm, 29 psi)
Unit: mm {in}
SERVICE LiMIT
1.5 (0.06)
Axle runout irra
Wheel rim runout Radial —
Axial — 1.0 {0.04}
Wheel balance weight — 60 g (2.1 oz) max.
Fork Spring frae jength 470.6 (18.53) 461 (18.15}
Tube runout — 0.20 (0.008)
Recommended fluid Fork fluid —
Fluid level 117 (4.6) se
Fluid capacity 346 + 2.5 cm® {11.7 + 0.08 US oz,
Steering head bearing pre-load
REAR WHEEL/SUSPENSION
ITEM
Minimum tire tread depth
12.2 + 0.09 Imp oz)
0.10 - 0.15 kgf (0.220 - 0.330 Ibf}
STANDARD
Cold tire pressure Driver only
200 kPa (2.0 kgf/cm’, 29 psi)
Driver and passenger
225 kPa (2.25 kgf/cm’, 33 psi)
Unit: mm (in}
SERVICE LIMIT
2.0 (0.08)
0.20 (0.008)
1.0 {0.04}
1.0 (0.04)
60 g (2.1 oz) max.
60 (2 3/8}
Axle runout —_—
Wheel runout Radial —
Axial —
Wheel balance weight —
Drive chain slack 25 —- 35 (1-1 3/8}
Drive chain link 110
Drive chain size | DID 520V6
| RK 520 SMOZ2
REGINA 135 ORNV2
1-10
GENERAL INFORMATION
BRAKE SYSTEM Unit: mm (in)
STANDARD SERVICE LIMIT
Specified brake fluid DOT3 or DOT4
Brake pad wear indicator — To groove
3.8 - 4.2 {0.15 - 0.17) 3.5 (0.13}
0.1 (0.004)
11.000 - 11.043 (0.4331 -— 0.4348) 11.055 (0.4352)
10.987 - 10.984 (0.4314 - 0.4324)
25.400 — 25.450 (1.0000 — 1.0020} 25.460 (1.0024)
25.335 — 25.368 (0.9968 — 0.9987} 25.31 (0.996}
DOT3 or DOT4 =
— To groove
3.8 - 4.2 (0.15 - 0.17) 3.5 {0.13}
Master cylinder |.D. 12.700 - 12.743 (0.5000 — 0.5017) _ | 12.755 (0.5022)
Master piston 0.D. 12.657 — 12.684 (0.4983 - 0.4994) 12.654 (0.4978)
Caliper cylinder |.D. 32.030 — 32.080 (1.2610 — 1.2630} 32.090 (1.2634)
Caliper piston 0.D. 31.948 — 31.998 (1.2578 — 1.2598} 31.94 (1.257)
CHARGING SYSTEM/ALTERNATOR
ITEM SPECIFICATIONS
Capacity 12V-6Ah
Current leakage 1.0 mA max
Voltage {20°C/68°F} Fully charged 13.0- 13.2 V
Needs charging Below 12.3 V
Brake disc thickness
Brake disc runout
Master cylinder I.D.
Master piston O.D. °
Caliper cylinder I.D.
Caliper piston O.D.
Specified brake fluid
Brake pad wear indicator
Brake disc thickness
Charging currant | Normal | 0.6-A4/5 - 10h
3.01 h max
Alternator Capacity 260 W/5,000 min” {rpm)
Charging coil resistance {20°C/68°F) 0.1-0.5 0
1-11
GENERAL INFORMATION
IGNITION SYSTEM
ITEM
Spark plug
ignition coil primary peak voltage
Ignition pulse generator peak voltage
Ignition timing “F” mark
Full advance
ELECTRIC STARTER/STARTER CLUTCH
ITEM
Starter motor brush langth
Starter clutch gear O.D.
SPECIFICATIONS
NGK DENSO
CR8EH-9 (NGK} U24FER-9 (DENSO)
Spark plug gap 0.8 - 0.9 mm (6.031 - 0.035 in}
12° + 1° BTDC at 1,500 + 100 min" (rpm)
BTDC 38°
STANDARD
10.00 — 10.05 (0.394 — 0.396)
45.657 — 45.673 (1.7975 — 1.7981)
Unit: mm {in}
100 V minimum
0.7 V minimum
SERVICE LIMIT
3.5 (0.14)
45.64 (1.797)
Starter clutch outer |.D.
LIGHTS/METERS/SWITCHES
iTEM
| Headlight (High/low beam) |
Bulbs
62.317 — 62.347 (2.4534 — 2.4546)
62.33 (2.454)
SPECIFICATIONS
12 V- 35/35 W x 2
Pasition light
12V-5Wx2
Brakeftail/license tight
Front turn signal light
Rear turn signal light
Instrument light
Turn signat indicator
High beam indicator
Neutral indicator
Temp indicator
Fuse Main fuse
12 V¥-21/5 W
12V-10Wx2
12V-10Wx2
12V-1.7Wx3
12V-2Wx2
12V-1.2W
12V-2W
12 V-1.7 W
30A
Sub fuse
WAx5
OFF > ON
ON -> OFF
Thermo
switch
112 — 118°C (234 - 444°F}
Below 108°C (226°F)
1-12
GENERAL INFORMATION
TORQUE VALUES
STANDARD —RGUE naa
FASTENER TYPE N-m (kgf-m, Ibf-ft) FASTENER TYPE [Nem tkgf-m, Ibfft)
5mm bolt and nut 5 (0.5, 3.6) 5mm screw 4 (0.4, 2.9}
6mm bolt and nut (Include SH 10 (1.0, 7) 6 mm screw 9 (0.9, 6.5}
flange bolt) 6 mm flange bolt and nut (Include 12 (1.2, 9}
8 mm bolt and nut 22 (2.2, 16) NSHF)
10 mm bolt and nut 34 (3.5, 25) 8 mm flange bolt and nut 26 (2.7, 20)
12 mm balt and nut 54 (5.5, 40} 10 mm flange bolt and nut 39 (4.0, 29)
* Torque specifications tisted below ara for important fasteners.
* Others should be tightened to standard torque values listed above.
NOTES: 1. Apply sealant to the threads.
2. Apply locking agent to the threads.
3. Apply molybdenum disulfide oil to the threads and flange surface.
4. Left hand threads.
5. Stake.
6. Apply oil to the threads and flange surface.
7. Apply clean engine oil to the O-ring.
8. UBS bolt.
9. U-nut.
10. ALOC bolt.
ENGINE
THREAD TORQUE
DIA. (mm) N-m (kgf-m, Ibf-ft)
MAINTENANCE:
Spark plug 12 (1.2, 9}
Crankshaft hole cap 15 (1.5, 11)
Timing hole cap 10 (1.0, 7}
Valve adjusting screw lock nut 17 (1.7, 12)
Oil drain bolt 25 (2.5, 18}
LUBRICATION SYSTEM:
Oil pump mounting bolt 14 (1.4, 10)
FUEL SYSTEM:
Caburetor insutator band screw
PAIR check valve cover bolt
COOLING SYSTEM:
Water pump drain bolt
Water pump impeller
Cooling fan nut
ENGINE REMOVAL/INSTALLATION:
Drive sprocket setting plate bolt
CLUTCH/GEARSHIFT LINKAGE:
Clutch center lock nut
Clutch pressure plate boit
Gear shift stopper arm pivot bolt
Gear shift cam plate bolt
5 (0.5, 3.6)
5 (0.5, 3.6}
ao
13 (1.3, 9)
12 (1.2, 9)
1 (0.1, 0.7}
—
oO QS
12 (1.2, 9}
108 (11, 80) NOTE 5, 6
12 {1.2, 9)
12 (1.2, 9) NOTE 6
23 (2.3, 17) NOTE 2
st
DHHS
1-13
—a,
GENERAL INFORMATION
ENGINE (Cont'd)
ITEM THREAD TORQUE
DIA. {mm} N-m {kgf-m, Ibf-ft)
CYLINDER HEAD/VALVE:
Cylinder haad side cover boit
Cylinder head cover bolt
Cam sprocket bolt
Cylinder head flange nut: 8 mm (0.3 in)
6 mm (0.2 in)
10 (1.0, 7)
10 (1.0, 7)
20 (2.0, 14}
32 (3.3, 24)
12 (1.2, 9}
12 (1.2, 9}
5 (0.5, 3.6)
12 (1.2, 9)
4 (0.4, 2.9)
On
—_
Ld
Camshaft holder bolt
Rocker arm shaft bolt
Cam chain tensioner lifter bolt
Cam chain tensioner lifter plug
CRANKCASE/TRANSMISSION/CRANKSHAFT:
Mainshaft bearing setting plate bolt
Shift drum bearing setting piate bolt
CHARGING SYSTEM/ALTERNATOR:
Flywheel nut 64 (6.5, 47)
Stator mounting bolt 12 (1.2, 9)
Ignition pulse generator mounting bolt 5 (0.5, 3.6)
Stator/Ignition pulse generator wire clamp bolt 5 (0.5, 3.6)
IGNITION SYSTEM:
Engine coolant temperature (ECT} sensor 23 (2.3, 17}
ELECTRIC STARTER/STARTER CLUTCH:
Starter motor terminal nut 12 (1.2, 9)
Starter motor front cover bolt 5 (0.5, 3.6)
Primary drive gear lock nut 88 (9.0, 65)
OTHERS:
Neutral switch 12 (1.2, 9}
Neutral switch terminal nut ~ 2 (0.2, 1.4)
Nf >
Ome on~na a
No
10 (1.0, 7)
10 (1.0, 7}
® oO
shinier, THREAD TORQUE
ITEM DIA. (mm) | Nem (kaf-m, Ibfft) | REMARKS
FRAME/BODY PANELS/EXHAUST SYSTEM:
Muffler band bolt 20 (2.0, 14)
Exhaust pipe joint nut 18 (1.8, 13}
Muffler mounting bolt 32 (3.3, 24)
ENGINE REMOVAL/INSTALLATION:
Front engine mounting nut
Rear upper engine mounting nut
Rear lower engine mounting nut
Engine hanger bracket bolt
FRONT WHEEL/SUSPENSION/STEERING:
Fork bolt
Fork socket bolt
Handlebar holder bolt
Steering stem nut
Steering top thread
Top bridge pinch bolt
Bottom bridge pinch bolt
Front axle bolt
Front axle pinth bolt 22 (2.2, 16)
Front brake disc bolt 42 (4.3, 31) NOTE 10
Throttle housing screw 4 (0.4, 2.9)
39 (4.0, 29)
39 (4.0, 29)
39 (4.0, 29)
18 (1.8, 13)
~- AD od ot
22 (2.2, 16)
20 (2.0, 14)
24 (2.4, 17)
103 (10.5, 76)
See page 12-26
26 (2.7, 20)
34 (3.5, 25)
66 (6.7, 48)
fe - PN A AH BN ND
1-14
GENERAL INFORMATION
FRAME (Cont'd) =e =
REAR WHEEL/SUSPENSION:
Rear axle nut 1 14 88 (9.6, 65) NOTES
Driven sprocket nut 6 10 64 (6.5, 47) NOTE 9
Rear brake disc bolt 4 8 42 (4.3, 31) NOTE 10
Shock absorber upper mounting nut 1 10 44 (4.5, 33) NOTE 9
Shock absorber lower mounting nut 1 10 44 (4.5, 33)
Swingarm pivot nut 1 14 88 (9.0, 65) NOTE 9
Chain slider screw 2 5 3 (0.3, 2.2}
Chain adjuster lock nut 2 6 10 (1.0, 7)
BRAKE SYSTEM:
Front brake oil balt 2 10 34 (3.5, 25)
Front master cylinder holder bolt 2 6 12 (1.2, 9)
Front master cylinder cover screw 2 4 2 (0.2, 1.4)
Front brake light switch screw 1 4 1 (0.1, 0.7)
Brake lever pivot nut 1 6 6 (0.6, 4.3)
Brake lever pivot bolt 7 6 1 (0.1, 0.7)
Front brake caliper mounting bolt 1 8 30 (3.1, 22} NOTE 10
Front caliper pin bolt (main} 1 8 18 (1.8, 13}
Front caliper pin bolt (sub) 1 8 23 (2.3, 17)
Front caliper pad pin 1 10 18 (1.8, 13}
Front caliper pad pin plug 1 10 2 (0.2, 1.4)
Rear brake reservoir tank bolt 1 6 12 {1.2, 9}
Rear brake oil bolt 2 10 34 (3.5, 25)
Rear master cylinder mounting bolt 2 6 12 (1.2, 9}
Rear master cylinder push rod nut 1 8 17 (1.7, 12)
Rear master cylinder cover screw 2 4 2 (0.2, 1.4)
Rear caliper pin bolt 1 8 17 (1.7, 12)
Rear caliper pad pin 1 10 17 (1.7, 12)
Rear caliper pad pin plug 1 10 2 (0.2, 1.4)
LIGHTS/METERS/SWITCHES:
Thermo switch 1 16 18 (1.8, 13)
OTHER FASTENERS:
Side stand pivot bolt 1 10 10 (1.0, 7}
Side stand lock nut 1 10 29 (3.0, 22) NOTE 9
Side stand switch bolt 1 6 10 (1.0, 7}
1-15
GENERAL INFORMATION
A Eee ee cr TT
TOOLS
NOTES: 1. Alternative tool.
2. Newly provided tool.
DESCRIPTION
Attachment, 22 x 24mm
Attachment, 24 x 26 mm
Attachment, 28 x 30 mm
Attachment, 32 x 35 mm
Attachment, 42 x 47 mm
Bearing installer 37.42
Bearing installer 37.5
Bearing remover head
Bearing remover head
Bearing remover head
Bearing remover shaft
Bearing remover shaft
Bearing remover shaft
Bearing remover weight
Carburetor float level gauge
Clutch center holder
Crank shaft assembly collar
Crank shaft assembly shaft
Driver
Driver shaft
Flywheel holder
Flywheel puller
Fork seal driver body
Fork seal driver attachment
Gear halder
Mechanical seal driver attachment
Mechanical seal driver
Peak voltage adapter
Pilot, 10 mm.
Pilot, 12 mm
Pilot, 15 mm
Pilot, 17 mm
Pilot, 20 mm
Pilot, 25 mm
Pilot screw wrench
Plate, 200 x 300 x 20
Snap ring pliers
Driver handle
Steering stem driver
Driver attachment
Steering stem cap nut wrench
Steering stem socket wrench
Universal bearing puller
Vacuum gauge attachment
Valve guide driver, 5mm
1-16
TOOL NUMBER
07746-0010800
07746-0010700
07746-1870106
07746-0010100
07746-0010300
07XMF-KGBO100
07XMF-KGB0200
07746-0050400
07936-GE00200
07936-KC 10200
07936-GE00100 .
07936-KC 10100
07746-0050100
07741-0010201
07401-0010000
07724-0050002
07965-VM00100
07965-VM00200
07749-0010000
07946-MJ00100
07725-0040000
07 KMC-HE00100
07747-0010100
07947-KA20200
07724-0010200
07945-4150400
07PMD-KBP0100
07HGJ-0020100
07746-0040100
07746-0040200
07746-0040300
07746-0040400
07746-0040500
07746-0040600
07908-4730002
07XMF-KGBO0300
07914-SA50001
07953-MJ 10200
07946-MB00000
07953-MJ10100
07716-0020400
07916-3710101
07631-0010000
07510-3000100
07942-MA60000
REMARKS
REF.SEC.
(Cont'd)
DESCRIPTION
Valve guide reamer
Valve spring compressor
Valve spring compressor attachment
Valve seat cutter
Seat cutter, 24.5 mm (45° IN)
Seat cutter, 22 mm (45° EX)
Flat cutter, 25 mm (32° IN}
Flat cutter, 22 mm (32° EX)
Interior cutter, 22 mm (60° IN/EX}
Cutter holder, 5 mm
TOOL NUMBER
07984-MA60001
07757-0010000
07959-KM30101
07786-0010160
07780-0010701
07780-0012000
07780-0012601
07780-0014202
07781-0010400
REMARKS
GENERAL INFORMATION
REF.SEC.
1-17
—
GENERAL INFORMATION
LUBRICATION & SEAL POINTS
ENGINE
LOCATION MATERIAL _ REMARKS
Camshaft camsurf/journals Molybdenum
Valve stem (valve guide sliding surface)/stem end disulfide oil (a mixture of
Rocker arm slipper surface 1/2 engine oil and 1/2
Rocker arm shaft sliding surface molybdenum disulfide
Connecting rod small end inner surface grease)
Clutch outer sliding surface
M-3, C-4, C-5 gear (shift fork grooves}
Clutch outer guide surface
Gear {engaging and bearing portion}
Piston pin outer surface
Gear shift fork inner surface and shaft
Piston pin hole and outer cylindrical surface Engine oil
Piston ring whole surface
Primary drive gear lock nut threads and seating surface
Flywheel lock nut threads and seating surface
Clutch disk lining surface
Cylinder stud bolt threads
Valve adjusting nut threads
Cam chain whole surface
Connecting rod bearing surface
Clutch center lock nut threads and seating surface
Oil pump inner rotor
Cylinder inner surface
Camshaft holdar bolt threads and seating surface
Clutch lifter piece outer surface
Clutch lifter arm shaft outer surface
Starter clutch sliding area
Each ball/needle bearing sliding area
Each O-ring
Gearshift spindle shaft outer surface
Oil strainer screen rubber frame
Scavenging pipe rubber parts
Right and left crankcasa mating surface Sealant
Thermo switch threads
Alternator and ignition pulse generator grommets
Water pump mechanical seal flange
Cam chain tensioner tighting bolt threads Locking agent
Gearshift cam ptate bolt threads
Mainshaft bearing set plate bolt threads
Gearshift drum bearing set plate bolt threads
Fan motor shaft threads
Cam sprocket bolt threads
Cylinder head cover gasket Honda Bond Aor
equivalent
1-18
LOCATION
Clutch lever pivot sliding surface
Throttle grip pipe rolled up portion
Rear brake pedai pivot sliding surface
Gearshift pedal pivot sliding surface
Side stand pivot sliding surface
Front wheel dust seal lip area
Rear wheel dust seal lip area
Rear wheel O-ring whole
Final driver flange gap with rear hub
Final driver flange dust seal lip area
Steering head upper bearing
Steering head lower bearing
Steering head dust seal lips
Rear caliper pin bolt
Rear master cylinder push rod contact area
Front brake lever pivot and piston contact area
Front brake lever pivot sliding area
Front fork oil seal lips
Swingarm pivot dust seal lips
Swingarm pivot bearing and center collar sliding
surface
Swingarm pivot bush and collar sliding surface
Speedometer gear box inside
Speedometer gear sliding portion
Steering top thraads
Front engine hanger bolt threads
Rear engine hanger bolt threads
Upper engine hanger bolt threads
Brake master cylinder pistons and cups
Rear caliper piston sliding surface
Throttle cable casting inside
Clutch cable casing inside
Caliper piston seal sliding surface
Caliper pin sliding surface
Final driven flange bolt threads
Rear caliper nut threads
Front caliper pin threads
Front caliper nut threads
Fork socket bolt threads
Handle grip rubber inside-surfaces
Front fork inside
MATERIAL
Multi-purpose grease
GENERAL INFORMATION
REMARKS
Grease
Engine oil
DOT 3 or DOT 4 brake fluid
Silicone grease
Locking agent
Honda band A or Cemedine
#540
Fork fluid
1-19
GENERAL INFORMATION
CABLE & HARNESS ROUTING
THROTTLE CABLES CLUTCH CABLE
iim
a
BRAKE HOSE LEFT HANDLEBAR
SWITCH WIRE
METER WIRE
>: LEFT FRONT
RIGHT FRONT , TURN SIGNAL WIRE
TURN SIGNAL WIRE
TURN SIGNAL
RELAY WIRE
1-20
GENERAL INFORMATION
THROTTLE CABLES
ENGINE STOP
7, SWITCH WIRE
(
ff
| MAIN WIRE HARNESS
LEFT HANDLEBAR A
SWITCH WIRE a
4
RADIATOR RESERVE
TANK OVER FLOW TUB
FUEL TUBE
SPEED SENSOR
WIRE
SIPHON TUBE
1-21
GENERAL INFORMATION
ENGINE COOLANT
TEMPLATURE SENSOR WIRE THERMO SWITCH
WIRE MAIN WIRE
THROTTLE CABLES HARNESS
STARTER GROUND WIRE
MOTOR WIRE
SIDE STAND
SWITCH WIRE
ALTERNATOR NEUTRAL SWITCH WIRE SPEED SENSOR WIRE
WIRE (IG TYPE ONLY)
1-22
WATER HOSE
GENERAL INFORMATION
SPEEDOMETER WIRE
1-23
GENERAL INFORMATION
REAR BRAKE
AIR SUPPLY HOSE
REAR SPARK PLUG WIRE
LIGHT SWITCH WIRE
FRONT SPARK PLUG
WIRE
a
f
:
. NY |
KH
:
. .
2
a ew
WATER TUBE
STARTING ENRICHMENT
{SE} VALUE CABLES
DRAIN TUBE
1-24
GENERAL INFORMATION
REAR BRAKE
LIGHT SWITCH
WIRE
REAR BRAKE HOSE
IGNITION CONTROL MODULE (ICM) WIRE
MAIN WIRE HARNESS
BATTERY NEGATIVE WIRE BATTERY POSITIVE WIRE
STARTER RELAY
SWITCH WIRE
1-25
SIGNAL WIRE
1-26
GENERAL INFORMATION
SOURCE OF EMISSIONS
The combustion process produces carbon monoxide and hydrocarbons. Controlling hydrocarbon emission is very
important because, under certain conditions, they react to form photechemical smog when subjected to sunlight.
Carbon monoxide does not react in the same way, but it is toxic.
Honda Moter Co., Ltd. utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide and hydro-
carbons.
CRANKCASE EMISSION CONTROL SYSTEM
The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions inte the atmospher.
Blow-by gas is returned to the combustion chamber through the air cleaner and carburetor.
AIR CLEANER CASE
CARBURETOR
BLOW-BY GAS
<I Frest AIR
1-27
GENERAL INFORMATION
EXHAUST EMISSION CONTROL SYSTEM (PULSE SECONDARY AIR INJECTION SYSTEM)
The exhaust emission control system consists of a secondary air supply system which introduces filtared air into the
axhaust bases in the exhaust port. Fresh air is drawn into the exhaust port whenever there is a negative pressure pulse
in the exhaust system. This charge of fresh air promotes burning of the unburned exhaust gases and changes a consid-
erable amount of hydrocarbons and carbon monoxide into relatively harmiess carbon dioxide and water vapor.
This model has the pulse secondary air injection (PAIR) control valve and PAIR check valve. Pair check valve prevents
reverse air flow through the system. The PAIJR control valve reacts to high intake manifold vacuum and will cut off the
supply of the fresh air during angine deceleration, thereby preventing afterburn in the exhaust system.
No adjustment to the pulse secondary air injection system should be made, although periodic inspection of the compo-
nents is recommended.
PULSE SECONDARY
AIR INJECTION (PAIR)
CHECK VALVE Mg
AIR CLEANER
PULSE SECONDARY
AIR INJECTION (PAIR)
CONTROL VALVE
EXHAUST PORT
1-28
SERVICE INFORMATION TAIL COVER/REAR FENDER
TROUBLESHOOTING REAR INNER FENDER/BATTERY 8OX
SEAT FRONT COWL
SIDE COVER FUEL TANK
FRONT FENDER MUFFLER/EXHAUST PIPE
REAR CARRIER
SERVICE INFORMATION
GENERAL
» Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area. Smoking
or allowing flames or sparks in the work area or where the gasoline is stored can cause a fire or explosion.
- Engine and exhaust system parts become very hot and remain hot for some time after the engine is run. Wear insu-
lated gloves or wait until the engine and exhaust system have cooled before handling these parts.
- if the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an
enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and
faad to death. Run the engine in an open area or with an exhaust evacuation system in an enclosed area.
+ This section covers removal and installation of the body panels, fuel tank and exhaust system.
+ Always replace the exhaust pipe gasket when removing the exhaust pipe from the engine.
» When installing the exhaust system, loosely install all of the exhaust pips fasteners. Always tighten the exhaust
clamps first, then tighten the mounting fasteners. If you tighten the mounting fasteners first, the exhaust pipe may
not seat properly.
+ Always inspect the exhaust system for leaks after installation.
TORQUE VALUES
Muffler band bolt 20 N-m {2.0 kgf-m, 14 Ibf-ft}
Exhaust pipe joint nut 18 N-m (1.8 kgf-m, 13 Ibf-ft}
Muffler mounting bolt 32 N-m (3.3 kgf-m, 24 Ibf-ft)
TROUBLESHOOTING
Excessive exhaust noise
* Broken exhaust system _
« Exhaust gas leak :
Poor performance
« Deformed exhaust system
« €xhaust gas leak
¢ Clogged muffler
2-1
FRAME/BODY PANELS/EXHAUST SYSTEM
SEAT
REMOVAL
Unlock the seat with the ignition key.
Pull the saat back and remove it.
INSTALLATION
Install the seat by inserting the groove to the prong on the eye Gs IGNITION
fual tank and the catches into the hooks of the frame.
Push the seat forward, then down to lock it.
SIDE COVER
Remove the seat (see above).
NOTE:
Be careful not to damage the bosses of the side cover.
Remove the bolt and screw.
Remove the boss of the side cover from the grommet and
remove the side cover.
Instatlation in the reverse order of removal.
SIDE COVER
BOSS/GROMMET
2-2
FRAME/BODY PANELS/EXHAUST SYSTEM
FRONT FENDER SPEED SENSOR CABLE GROMMET
Remove the speed sensor cable grommet.
Remove the bolts, brake hose cramp, front fender and front
fender stay.
®
FRONT
FENDER
Installation is in the reverse order of removal.
FENDER
BRAKE HOSE CRAMP STAY
REAR CARRIER
Remove the seat (page 2-2}.
Remove the bolts.
Remove the rear carrier, washers and collars.
Panes WASHERS
Installation is in the reverse order of removal.
COLLARS —"'@
FRAME/BODY PANELS/EXHAUST SYSTEM
TAIL COVER/REAR FENDER
REMOVAL aie COLLARS TAIL COVER/REAR FENDER
Remove the seat (page 2-2}..
Remove the rear carrier {page 2-3).
Remove the balts.
Disconnect the tail/orake light and rear turn signal connec-
tors.
Remove the tail cover/rear fender.
installation is in the reverse order of removal.
DISASSEMBLY
Remove the screws, bolts and rear tail cover from the rear TAIL COVER
fender.
Remove the screws and turn signal fights. BOLTS SCREW
Installation is in the reverse order of removal.
TURN SIGNAL LIGHT
REAR FENDER
2-4
FRAME/BODY PANELS/EXHAUST SYSTEM
REAR INNER FENDER/BATTERY BOX IGNITION
CONTROL
Remove the following:
— Seat (page 2-2)
— Left side cover (page 2-2)
— Battery (page 15-4)
— Regulator/rectifier (page 15-7)
— Ignition control module {page 16-9)
— Starter relay switch (page 17-16}
BATTERY CASE KEY CYLINDER
Remove the battery mount bolts and battery case.
Disconnect the wire and remove the key cylinder. |
Remove the mount bolts/collars and rear inner fender.
Installation is in the reverse order of ramoval.
REGULATOR/RECTIFIER
BATTERY CASE MOUNT BOLTS
BOLTS/COLLARS
REAR FENDER MOUNT
| oe re
FRAME/BODY PANELS/EXHAUST SYSTEM
FRONT COWL
WINDSHIELD SCREEN
CAUTION: SCREWS WINDSHIELD SCREEN
Do not scratch and damage the windshield screen.
Remove the screws, washers and windshield screen.
Remove the setting nut. WASHERS
Installation is in the reverse order of removal.
SETTING NUT
INNER CENTER COWL
Remove the lower bolts of the front cowl assembly.
Remove the trim crips and inner center piece.
Remove the trim crips and inner center cowl.
Installation is in the reverse order of removal.
INNER CENTER
COWL
TRIM CRIPS INNER
ENTER PIECE
2-6
FRAME/BODY PANELS/EXHAUST SYSTEM
FRONT COWL ASSEMBLY TRIM CRIPS P METER LID
REMOVAL
Remove the inner center piece and inner center cowl (page
2-6).
Remove the trim crips and meter lid.
Remove the combination meter (page 18-6).
Remove the upper bolts/collars, socket bolts and front cow! UPPER BOLTS/
assembly, <P COWL rd COLLARS
, k ASSEMBLY
NOTE: (2 , Ca eo
Be careful not to damage the front cowl assembly. shea
ae a
Disconnect the head tight, position light 4P connector and A = a
left and right turn signal tight 2P connectors.
SOCKET BOLTS
DISASSEMBLY
Remove the windscreen {page 2-6). HEADLIGHT
Remove the bolts and headlight.
Remove the trim crips, screws and meter panel.
Remove the left and right front cowls.
Remove the screws and turn signal lights.
Installation is in the reverse order of removal.
TURN SIGNAL LIGHT LEFT FRONT COWL
FRAME/BODY PANELS/EXHAUST SYSTEM
FUEL TANK
REMOVAL
A WARNING
Gasoline is extremely flammable and is explosive under
certain conditions. Work in a well ventilated area. Smoking
or allowing flames or sparks in the work area or where the
gasoline is stored can cause a fire explosion.
CAUTION:
Do not damage the front cow! assembly and fuel tank.
Remove the seat (page 2-2).
Turn the fuel vaive “OFF”.
Disconnect the fuel tube from the fuel joint.
NOTE:
At removal, be careful not to damage the fuel sensor 2P
connector and wire.
Remove the lower bolts and socket bolts from the front
cowl assembly.
Remove the bolt, collar and fuel tank.
Disconnect the breather tube.
DISASSEMBLY
Loosen the fuel valve nut and remove the fuel valve.
Remove the strainer screen and O-ring.
Check the fuel strainer screen for clogs or damage and
clean or replace if necessary.
Install the new O-ring to the fuel strainer screen.
Attach the fuel strainer screen to the fuel valve and install
to the fuel tank.
NOTE:
Always replace the O-ring with new one.
Tighten the fuel valve nut securely.
BREATHER TUBE FUEL TANK
BOLT
ee
SOCKET BOLT
BREATHER -
FUEL JOINT TUBE
FUEL TANK
STRAINER SCREEN
FUEL VALVE
FUEL VALVE NUT
FRAME/BODY PANELS/EXHAUST SYSTEM
MUFFLER/EXHAUST PIPE
REMOVAL
MUFFLER MOUNTING BOLTS
>———
MUFFLER
A WARNING
Do not service the exhaust system while it is hot.
Remove the seat (page 2-2).
Remove the side covers (page 2-2).
Loosen the muffler band bolt.
Remove tha muffler mounting bolts and muffler.
Loosen the rear exhaust pipe band bolt and remove the
Pei rs . GASKET
rear exhaust pipe joint nuts, gasket and rear exhaust pipe. :
ia”
LOA
— B
REAR EXHAUST PIPE ‘EXHAUST REAR EXHAUST
BAND BOLT PIPE PIPE JOINT NUTS
Remove the front exhaust joint nuts, gasket and front
exhaust pipe.
FRONT EXHAUST
FRONT EXHAUST PIPE PIPE JOINT NUTS
ee -—— —- -------
FRAME/BODY PANELS/EXHAUST SYSTEM
INSTALLATION
REAR EXHAUST @
PIPE JOINT NUTS GASKET
MUFFLER
MUFFLER
MOUNTING gg SERIE!
BOLT
BAND BOLT \
e je FRONT EXHAUST
oy PIPE JOINT NUT
BAND BOLT
GASKETS FRONT EXHAUST PIPE
Replace the gaskets with new ones.
Installation is in the reverse order of removal.
Tighten the bolts and nuts to their specified torque.
TORQUE:
Exhaust pipe joint nut: 18 N-m (1.8 kgf-m, 13 Ibf-ft}
Muffter band bolt: 20 N-m (2.0 kgf-m, 14 Ibf-ft}
Muffler mounting boit: 32 N-m (3.3 kgf-m, 24 Ibf-ft)
2-10
SERVICE INFORMATION
MAINTENANCE SCHEDULE
FUEL LINE
THROTTLE OPERATION
CARBURETOR CHOKE
AIR CLEANER
SPARK PLUG
VALVE CLEARANCE
ENGINE OIL/OIL FILTER
CARBURETOR SYNCHRONIZATION
ENGINE IDLE SPEED
RADIATOR COOLANT
COOLING SYSTEM
SECONDARY AIR SUPPLY SYSTEM
SERVICE INFORMATION
GENERAL
#& WARNING
3. MAINTENANCE
DRIVE CHAIN
DRIVE CHAIN SLIDER
BRAKE FLUID
BRAKE PADS WEAR
BRAKE SYSTEM
BRAKE LIGHT SWITCH
HEADLIGHT AIM
CLUTCH SYSTEM
SIDE STAND
SUSPENSION
NUTS, BOLTS, FASTENERS
WHEELS/TIRES
STEERING HEAD BEARINGS
+ Gasoline is extremely flammable and is explosive under certain conditions. Work in a weil ventilated area. Smoking
or allowing flames or sparks in the work area or where the gasoline is stored can cause a fire or expfosion.
+ ff the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an
enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and
jead to death. Run the engine in an open area or with an exhaust evacuation system in an enclosed area.
CAUTION:
Using coolant with silicate inhibitors may cause premature wear of water pump seals or blockage of radiator passage.
Using tap water may cause engine damage.
* Place the motorcycle on a level ground before starting any work.
SPECIFICATIONS _
ITEM
SPECIFICATIONS
Throttle grip free play
2-6mm (1/16 - 1/4 tn}
Spark plug | Standard
CR8EH-9 (NGK} U24FER-9 (DENSO)
Spark plug gap
0.80 - 0.90 mm (0.031 — 0.035 in)
Valve clearance | IN
0.15 + 0.02 mm {0.006 + 0.001 in}
0.24 + 0.02 mm (0.009 + 0.001 in}
3-1
—————_——— $$ er =
MAINTENANCE
ye
ITEM SPECIFICATIONS
Engine oll eapadiy
At disassambly 1.5 titer (1.6 US qt, 1.3 Imp qt)
At filter change 1.2 liter (1.3 US qt, 1.1 Imp qt)
Recommended engine oil HONDA 4-stroke oil or equivalent motor oi! API service clas-
sification SE, SF or SG Viscosity: SAE 10 W-40
Carburetor vacuum difference 4 kPa (30 mm Hg, 1.18 in Hg)
Engine idie speed 1,500 + 100 min” (rpm}
Drive chain slack 25 — 35 mm (1-1 3/8 in)
Drive chain link 110 links
Recommended brake fluid DOT 3 OR DOT 4
Clutch iever free play 10 ~ 20 mm (3/8 — 13/16 in)
Tire size 100/90 - 18 56P
130/80 - 17 65P
Tire brand BRIDGESTONE TRAIL WING-53G/PIRELLI MT90ST
BRIDGESTONE TRAIL WING-54/PIRELLI MT90ST
Cold tire pressure | Up to 90 kg (200 Ib) Front | 200 kPa (2.00 kgf/cm?, 29 psi)
eed Rear 200 kPa (2.00 kgf/cm’, 29 psi)
Up to maximum
weight capacity 225 kPa (2.25 kgi/em?, 33 psi)
Minimum tire tread depth 0.8 mm {0.03 in}
0.8 mm (0.03 in}
TORQUE VALUES
Spark plug 12 N-m (1.2 kgf-m, 9 Ibf-ft}
Valve adjusting screw lock nut 17 N-m (1.7 kgf-m, 12 Ibf-ft} Apply oil to the threads and seating surface
Timing hole cap 10 N-m (1.0 kgf-m, 7 Ibf-ft) Apply molybdenum oil solution to the threads
Crankshaft hola cap 15 N-m (1.5 kgf-m, 11 Ibf-ft) Apply molybdenum oil solution to the threads
Oil drain bolt 25 N-m (2.5 kgf-m, 18 Ibf-ft)
Rear axle nut 88 N-m (9.0 kgf-m, 65 Ibf-ft)
MAINTENANCE
MAINTENANCE SCHEDULE
Perform the Pre-ride inspection in the Owner’s Manual at each scheduled maintenance period.
|: Inspect and Clean, Adjust, Lubricate or Replace if necessary.
C: Clean. R: Replace. A: Adjust. L: Lubricate.
The following items require some mechanical knowledge. Certain items {particularly those marked * and **} may
require more technical information and tools. Consult their authorized HONDA dealer.
FREQUENCY WHICHEVER COMES FIRST => ODORMETER READING (NOTE 1)
ie x 1,000 km
NOTE x 1,000 mi
MONTHS
THROTTLE OPERATION
CARBURETOR CHOKE
AIR CLEANER
VALVE CLEARANCE
ENGINE OIL
CARBURETOR SYNCHRONIZATION
ENGINE IDLE SPEED Eee oars:
RADIATOR COOLANT
SECONDARY AIR SUPPLY SYSTEM = 1 | 315 |
DRIVE CHAIN | EVERY 1,000 km (600 mi) I,L| 3-16
BRAKE SYSTEM
BRAKE LIGHT SWITCH ne
HEADLIGHT AIM |
CLUTCH SYSTEM ee eee
SIDE STAND Meme oD
SUSPENSION |
NUTS, BOLTS, FASTENERS ie
WHEELS/TIRES
|** | STEERING HEAD BEARINGS |
* Should be serviced by an authorized HONDA dealer, unless the owner has proper tools and service data and is
mechanically qualified.
**In the interest of safety, we recommend these items be serviced only by an authorized HONDA dealer.
NOTES: 1. At higher odometer reading, repeat at frequency interval established here.
2. Service more frequently when riding in unusually wet or dusty areas.
3. Replace every 2 years, or at indicated odometer interval, whichever comes first. Replacement requires
mechanical skill.
3-3
MAINTENANCE
FUEL LINE
Gasoline is extremely flammable and is explosive under
certain conditions. KEEP OUT OF REACH OF CHILDREN.
FUEL LINE
Check the fuel line for deterioration, damage or leakage.
Replace the fuel line if necessary.
THROTTLE OPERATION
Check for any deterioration or damage to the throttle
cables.
Check the throttle grip for smooth operation. Check that the
throttle grip returns from the full open to the full closed
position smoothly and automatically in all steering posi-
tions.
If the throttle grip does not return properly, lubricate the
throttle cable, overhaul and lubricate the throttle grip hous-
ing.
For cable lubrication: Disconnect the throttle cables at their
upper ends (page 12-4). Thoroughly lubricate the cables
and their pivot points with a commercially available cable
lubricant or a light weight oil.
If the throttle grip still does not return properly, replace the
throttle cables.
Reusing a damaged or abnormally bent or kinked throttle
cable can prevent proper throttle side operation and may
lead to a loss of throttle control while riding.
With the engine idling, turn the handlebar all the way to the
right and left to ensure that idle speed does not change.
If idle speed increases, check the throttle grip free play and
the throttle cable connection.
Measure the throttle grip free play at the throttle grip
flange.
FREE PLAY: 2 - 6 mm (1/16 - 1/4 in)
MAINTENANCE
Throttle grip free play can be adjusted at either end of the
throttle cable. Minor adjustments are made with the upper
adjuster.
Loosen the lock nut and turn the adjuster to obtain the free
play.
After the adjustment, tighten the lock nut securely and
reposition the boot properly.
LOCK NUT
ADJUSTER
Major adjustments are mada with the lower adjuster.
Loosen the lock nuts and tusn the adjusters to obtain the ADJUSTERS
free play.
Tighten the lock nuts after the adjustment has been made.
Recheck the free play.
CARBURETOR CHOKE
STARTING ENRICHMENT (SE) VALVE
The choke system uses a fuel enriching circuit controlled by
an SE valve. The SE valve opens the enriching circuit via a
cable when the choke knob on the left side of the carburetor
is pulled.
Check for smooth operation of the choke knob.
Check for any deterioration or damage to the choke cable.
If the operation is not smooth, lubricate the choke cable and
choke knob sliding surface with a commercially available
cable lubricant or a light weight oil.
RUBBER COVER
ADJUSTER
MAINTENANCE
AIR CLEANER ~~ _ AIR CLEANER HOUSING COVER
Remove the fusl tank (page 2-8), ‘
Remove the six screws and air cleaner housing cover.
Remove and discard the air cleaner element in accordance
z 3 ELEMENT
with the maintenance schedule.
Also replace the air claaner element any time it is exces-
sively dirty or damaged.
Install the ramaved parts in the reverse order of removal.
SPARK PLUG
FRONT SIDE:
CAUTION:
Do not damage the front cowl.
Remove the front cowl lower bolts.
Remove tha trim clip from the inner center cowl (page 2-6)
and disconnect the boss of the front cowl from the grom-
met of the fuel tank.
Disconnect the front spark plug cap.
REAR SIDE:
Disconnect the rear spark plug cap.
NOTE:
Clean around the seat of the plug hole with compressed air
before removing, and be sure that no debris enters the
combustion chamber,
Remove the spark plugs using the spark plug wrench or an
equivalant.
Inspect or replace as described in the maintanance sched-
ule (page 3-3).
3-6
MAINTENANCE
INSPECTION
. SPARK PLUG
Check the following and replace if necessary (recommend-
ed spark plugs: page 3-1).
* Insulator for damage
¢ Electrodes for wear
* Burning condition, coloration;
— dark to light brown indicates good condition.
— excessive lightness indicates malfunctioning ignition
system or fearn mixture.
— wet or black sooty deposit indicates over-rich mixture.
ELECTRODES
REUSING A SPARK PLUG PLUG GAP
0.80 - 0.90 mm
Clean the spark plug electrodes with a wire brush or spark (0.031 — 0.035 in)
plug cleaner.
Check the gap between the center and side electrodes with
a wire-type feeler gauge. If necessary, adjust the gap by
bending the side electrodes carefully.
SPARK PLUG GAP: 0.80 - 0.90 mm (0.031 — 0.035 in}
CAUTION:
To prevent damage to the cylinder head, hand tighten the
spark plug before using a wrench to tighten to the speci-
fied torque.
Reinstall the spark plug in the cylinder head and hand tight-
en, then torque to specification.
TORQUE: 12 N-m (1.2 kgf-m, 9 Ibf-ft}
SPARK PLUG CAP
ik ow
SPARK PLUG CA
REPLACING A SPARK PLUG =
CAUTION:
Do not overtighten the spark plug.
Remove the spark plug (page 3-6).
Install and hand tighten the new spark plug, then tighten it
about 1/2 of a turn after the sealing washer contacts the
seat of the plug hole.
neaagell
B SPARK PLUG Mayet
3-7
MAINTENANCE
VALVE CLEARANCE
INSPECTION
NOTE:
* Inspection and adjustment of the valve clearance can be
done with engine in the frame.
* Inspect and adjust the valve clearance while the engine
is cold (below 35°C/95°F).
Remove the following:
— fuel tank (page 2-8).
— Radiator (page 6-8).
Remove the crankshaft hole cap and timing hole cap.
REAR CYLINDER HEAD
Rotate the flywheel counterclockwise to align the “RT” bey.
mark with the index mark on the left crankcase cover. RT" MARK
Make sure the piston is at TDC {Top Dead Cener) on the
compression stroke.
FRONT CYLINDER HEAD
Rotate the flywheel counterclockwise to align the “FT”
mark with the index mark on the left crankcase cover.
“FT” MARK
Make sure the piston is at TDC (Top Dead Cener) on the
compression stroke.
Inspect the clearance of all two valves by inserting a feeler
gauge between the adjusting screw and the valve.
VALVE CLEARANCE:
IN: 0.15 + 0.02 mm (0.006 + 0.001 in)
EX: 0.24 + 0.02 mm (0.009 + 0.001 in)
3-8
MAINTENANCE
ADJUSTMENT
Adjust by loosening the lock nut and turning the adjsting
screw until there is a slight drag on the feeler gauge.
NOTE:
Apply oil to the lock nut threads.
Hold the adjusting screw and tighten the lock nut.
TORQUE: 17 N-m (1.7 kgf-m, 12 Ibf-ft)
Install the cylinder head covers (page 9-25).
Apply grease to the timing hole cap, crankshaft hole cap
threads and O-rings.
Install and tighten the caps to the specified torque.
TORQUE:
Timing hole cap: 10 N-m (1.0 kgf-m, 7 Ibf-ft)
Crankshaft hole cap: 15 N-m (1.5 kgf-m, 11 Ibf-ft)
Install the following:
— Radiator (page 6-12).
— fuel tank (page 2-3).
CRANKSHAFT
HOLE CAP
ENGINE OIL/OIL FILTER
INSPECTION
A WARNING
¢ ff the engine must be running to do some work, make
sure the area is well-ventilated. Never run the engine in
an enclosed area. The exhaust contains poisonous car-
bon monoxide gas that may cause loss of consciousness
and lead to death. Run the engine in an open area or
with an exhaust evacuation system in an enclosed area.
+ Engine and exhaust system parts become very hot and
remain hot for some time after the engine is run. Wear
insulated gloves or wait until the engine and exhaust
system have cooled before handling these parts.
3-9
MAINTENANCE
NOTE:
* The oil level cannot be correctly measured if the motor-
cycle is not supported perfectly upright on a level sur-
face.
* As the oil is gradually consumed, it is necessary to peri-
odically check the oil level and replenish the oil volume
to its proper level.
* Hf the oil level is too high, overall engine performance
and the actuation of the clutch may be effected. Too little
oil may cause engine overheating as well as premature
wear to various parts.
* If a different brand or grade of oil or low quality oil is
mixad when adding oil, the lubricating function deterio-
rates.
Place the motorcycle on level ground upright.
Check tha oil level through the inspection window.
lf the oil level is below or near the lower level iine, remove
the oil filler cap and add the recommended oil up to the
upper level.
RECOMMENDED ENGINE OIL:
HONDA 4-stroke oil or equivalent motor oil
API service classification: SE, SF or SG
Viscosity: SAE 10W - 40
NOTE:
Other viscosities shown in the chart may be used when the
average temperature in your riding area is within the indi-
cated range.
Check the O-ring.
Reinstall the filler cap.
ENGINE OIL CHANGE
Place the motorcycle on the level ground upright.
Warm up the engine.
Place an oil drain pan under the engine to catch the oil,
then remove the oil drain bolt and ail filler cap/dipstick.
After the engine oil has been drained out, hold the motorcy-
cle upright securely for 10 - 15 seconds to drain the engine
oil completely.
CAUTION:
Support the motorcycle securely with a hoist or equivalent.
After draining the oil completely, check that the sealing
washer on the drain bolt is in good condition and replace if
necessary.
Tighten the drain bolt to the specified torque.
TORQUE: 25 N.m (2.5 kgf-m, 18 ibf-ft)
FILLER CAP
INSPECTION WINDOW LOWER LEVEL
OIL VISCOSITIES
DRAIN BOLT
3-10
MAINTENANCE
Fill the crankcase with recommended engine oil. FILLER CAP
OIL CAPACITY:
1.1 liter {1.2 US qt, 1.0 Imp qt} at draining
1.5 liter (1.6 US qt, 1.3 Imp qt) at disassembly
1.2 liter (1.3 US qt, 1.1 Imp qt) at oil filter change
Install the ail filler cap.
Start the engina and let it idle for 2-3 minutes.
Stop the engine and wait a few minutes, then check that the
oil level is at the upper level line in the inspaction window.
Check that there are no oil leaks. INSPECTION WINDOW
OIL FILTER CHANGE
Drain the engine oi! (page 3-10}.
Remove the following:
— cover bolts
— filter cover with O-ring
— oil filter
— spring
Apply engine oil to a new O-ring and install it in the filter
cover groove.
Install the spring between the lugs and a new oil filter with
the “OUT-SIDE” mark facing out, and set the filter cover
onto filter and tighten the two bolts securely.
SPRING
CAUTION:
installing the oil filter backwards will result in severe
engine damage.
Fill the engine oil (page 3-11}.
LOWER LEVEL
“OUT SIDE” MARK
3-11
MAINTENANCE
CARBURETOR SYNCHRONIZATION
NOTE:
* Perform this maintenanca with the engine at normal
operating temperature and transmission in neutral.
* It is not necessary to remove the carburetors when per-
form this maintenance.
Disconnect the vacuum tube from the vacuum joint pipe of
the rear cylinder head.
Remove the screw and washer from the front cylinder head
vacuum port.
Install the vacuum gauge attachment into the vacuum port.
TOOL:
vacuum gauge attachment 07510 - 300010
Connect the vacuum gauge tubes to the attachment and
vacuum joint pipe.
Start the engine and adjust the idle speed with the throttle
stop screw.
IDLE SPEED: 1,500 + 100 min“ {rpm}
Check the difference between the front and rear carbure-
tors.
CARBURETOR VACUUM DIFFERENCE:
4 kPa (30 mm Hg, 1.18 in Hg)
NOTE:
The base carburetor is the front carburetor.
Synchronize to specification by turning the synchronization
adjusting screw.
Snap the throttle grip several times.
Recheck the idfe speed and synchronization.
Remove the vacuum gauge and attachment.
Install and tighten the vacuum port screw.
Connect the vacuum tube to the vacuum joint pipe of the
rear cylinder head.
3-12
ADJUSTING SCREW
ENGINE IDLE SPEED
ff the engine must be running to do some work, make sure
the area is well-ventilated. Never run the engine in an
enclosed area. The exhaust contains poisonous carbon
monoxide gas that may cause loss of consciousness and
lead to death. Run the engine in an open area or with an
exhaust evacuation system in an enclosed area.
NOTE:
* Perform this maintenance with the engine at normal
operating tamperature and transmission in neutral. Place
the motorcycle on a level surface.
+ Engine must be warm for accurate adjustment.
Ten minutes of stop-and-go riding is sufficient.
Warm up the engine and shift the transmission into neutral.
Place the motorcycle on its side stand.
Check the idle speed and adjust by turning the throttle stop
screw control knob if necessary.
IDLE SPEED: 1,500 = 100 min“ {rpm}
RADIATOR COOLANT
LEVEL CHECK
+ Wait until the engine is cool before removing the radia-
tor cap. Removing the cap while the engine is hot and
the coolant is under pressure may cause serious scald-
ing.
° Radiator coolant is poisonous. Take care to avoid get-
ting coolant in your eyes, on your skin, or on your
clothes.
» if coolant gets in your eyes; flush repeatedly with water
and contact a doctor immediately.
« Hf coolant is accidentally swallowed, induce vomiting
and contact a doctor immediately.
« KEEP OUT REACH OF CHILDREN.
Check the coolant level of the reserve tank with the engine
running at normal operating temperature.
The level should be between the “UPPER” and “LOWER”
level lines with the motorcycle in-a vertical position on a
fiat, level surface.
MAINTENANCE
RESERVE TANK
“LOWER?” LEVEL
3-13
MAINTENANCE
If necessary, remove the reserve tank cap and fill to the
“UPPER” level line with a 50-50 solution of distilled water
and recommended antifreeze (coolant mixture preparation:
page 6-4).
CAUTION:
Using coolant with silicate inhibitors may cause premature
wear of water pump seals of blockage of radiator pas-
sages. Using tap water may cause engine damage.
Check to see if there are any coolant leaks when the coolant
level decreases very rapidly.
If the reserve tank becomes completely empty, there is a
possibility of air getting into the cooling system.
Be sure to remove all air from the cooling system as
described on page 6-5.
COOLING SYSTEM
To prevent injury, keep your hands and clothing away from
the cooling fan. It may start automatically, without warn-
ing.
Remove the inner center cowl (page 2-6).
Check the radiator air passage for clogging or damage.
Straighten bent fins with a small, flat blade screwdriver and
remove insects, mud or other obstructions with com-
pressed air or low pressure water.
Replace the radiator if the air flow is restricted over more
than 20% of the radiating surface.
For radiator replacement, refer to page 6-8.
RESERVE TANK CAP
3-14
MAINTENANCE
Check for any coolant leakage from the water pump (see
page 6-13), water hose and hose joints.
Make sure the hoses ara in good condition; they should not
show any signs of deterioration.
Replace any hose that shows any sign of deterioration.
Check that all hose clamps are tight.
WATER PUMP
For radiator replacement, refer to page 6-8.
SECONDARY AIR SUPPLY SYSTEM
NOTE:
* This model is equipped built-in secondary air supply sys-
tem. The pulse secondary air supply system is located on
the cylinder head cover.
« The secondary air supply system introduces filtered air
into exhaust gases in the exhaust port. The secondary air
is drawn into the exhaust port whenever there is nega-
tive pressure pulse in the exhaust system. This charged
secondary air promotes burning of the unburned
exhaust gases and changes a considerable amount of
hydrocarbons and carbon monoxide into relatively harm-
less carbon dioxide and water.
PAIR CHECK VALVE
Remove tha fuel tank {page 2-5).
Check the air injection hoses and pipes between the pulse
secondary air injection (PAIR) control valve and exhaust
port for deterioration, damage or loose connections. Make
sure that the hoses are not cracked.
NOTE:
If the hoses show any signs of heat damage, inspect the
PAIR check valves {page 5-20).
Check the air suction hose between the air cleaner housing
and PAIR control valve for deterioration, damage or loose
connections. Make sure that the hoses are not linked,
pinched or cracked.
For PAIR control valve inspection, see page 5-20.
PAIR CONTROL VALVE
MAINTENANCE
DRIVE CHAIN
DRIVE CHAIN SLACK INSPECTION
A WARNING
Never inspect and adjust the drive chain while the engine
is running.
Turn off the engine, place the motorcycle on its side stand
and shift the transmission into neutral. Check the slack in
the drive chain lower run midway between the sprockets.
CHAIN SLACK: 25 - 35 mm (1 - 1 3/8 in)
CAUTION:
Excessive chain slack, 60 mm (2 3/8 in) or more, may dam-
age the frame.
ADJUSTMENT
Loosen the rear axle nut.
Turn both adjusting nuts until the correct drive chain slack
is obtained.
Make sure the index marks on the both adjusters are
aligned with the rear edges of the axle slots in the
swingarm.
Tighten the rear axle nut to the specified torque.
TORQUE: 88 N-m (9.0 kgf-m, 65 Ibf-ft)
Tighten both adjusting nuts.
Recheck the drive chain slack and free wheel rotation.
Check the rear brake pedal free play (page 3-21), adjust if
necessary.
Lubricate the drive chain with #80—90 gear oil or drive
chain lubricant designed specifically for use with O-ring
chains.
Wipe off the excess oil.
CLEANING AND LUBRICATION
Clean the chain with non-flammable or high flash point sol-
vent and wipe it dry.
Be sure the chain has dried completely before lubricating.
Inspect the drive chain for possible damage or wear.
Replace any chain that has damaged rollers, loose fitting
links, or otherwise appears unserviceable.
Installing a new chain on badly worn sprockets will cause
the new chain to wear quickly.
Inspect and replace sprocket as necessary.
NON-FLAMMABLE OR HIGH FLASH
POINT SOLVENT
WIPE AND DRY SRC — ey
26
3-16
Lubricate the drive chain with # 80 - 90 gear oil or drive
chain lubricant designed specifically for use with O-ring
chains. Wipe off the excess oil or chain lubricant.
SPROCKETS INSPECTION
Inspect the drive and driven sprocket teeth for wear or dam-
age, replace if necessary.
Never use a new drive chain on worn sprockets.
Both chain and sprockets must be in good condition, or the
new replacement chain will wear rapidly.
REPLACEMENT
This motorcycle uses a drive chain with a staked master
link.
Loosen the drive chain (page 3-16).
Assemble the special tool as shown.
TOOL:
Drive chain tool set 07HMH - MR10103
NOTE:
When using the special tool, follow the manufacture’s
instruction. i
MAINTENANCE
LUBRICATE
# 80 - 90 GEAR OIL OR
DRIVE CHAIN LUBRICANT
DAMAGE
DRIVE CHAIN TOOL SET
3-17
ee aro a ea ee Oe TE
MAINTENANCE
Locate the crimped pin ends of the master Jink from the
outside of the chain, and remove the link with the drive MASTER LINK
chain tool set.
TOOL:
Drive chain tool set O07HMH —- MR10103
Remove the drive chain.
DRIVE CHAIN TOOL SET
Remove the excess drive chain links from the new drive
chain with the drive chain tool set.
NOTE:
Include the master link when you count the drive chain
links.
STANDARD LINKS: 110 links
REPLACEMENT CHAIN:
DID: 520 V6
RK: 520SMOZ2
REGINA: 135 ORNV2
CAUTION:
Never reuse the oil drive chain, master link, master link
plate and O-rings.
Assemble the new master link, O-rings and plate.
CAUTION:
insert the master link from the inside of the drive chain,
and install the plate with the identification mark facing the
outside.
Assemble and set the drive chain tool set.
TOOL:
Drive chain toal set O7HMH ~ MR10103
Make sure that the master link pins are installed properly.
Measure the master link pin length projected from the MASTER LINK PINS
plate.
STANDARD LENGTH:
DID: 1.15 -— 1.55 mm (0.045 - 0.061 in}
RK: 1.20 - 1.40 mm [60.047 — 0.055 in)
REGINA: Not applicable
3-18
MAINTENANCE
Stake the master link pins with the drive chain tool set.
MASTER LINK
TOOL:
Drive chain tool set O7HMH - MR10103
NOTE:
To prevent over staking, stake gradually checking the diam-
eter of the staked area using slide calipers.
Make sure that the pins are staked properly by measuring
the diameter of the staked area using a slide caliper.
DIAMETER OF THE STAKED AREA:
DID: 5.40 - 5.46 mm (0.213 - 0.215 in}
RK: 5.50 -5.80 mm (0.217 - 0.228 in)
REGINA: Not applicable
After staking, check the staked area of the master link for
cracks.
If there is any cracking, replace the master link, O-rings and
plate.
CAUTION:
A drive chain with a clip-type master link must not be
used.
DRIVE CHAIN SLIDER
ys
Remove the left rear cover (page 7-3). ii Va,
Check the drive chain slider for wear of damage.
Replace the drive chain slider if it is worn to the wear limit
or it has been damaged.
Install the left raar cover (page 7-6).
OD OPO Oni;
MAINTENANCE
BRAKE FLUID
CAUTION:
° Do not remove the cover or cap unless the reservoir is
level because fluid may spill out.
« Do not mix different types of fluid, as they are not com-
patible with gach other.
* Do not allow foreign material to enter the system when
filling the reservoir.
« Avoid spilling fluid on painted, plastic or rubber parts.
Place a rug over these parts whenever the system is ser-
viced.
NOTE:
« When the fluid level is low, check the brake pads for
wear
(paga: 3-20}. A low fluid level may be due to wear of the’
brake pads. If the brake pads are worn, the caliper piston
in pushed out, and this accounts for a low reservoir level.
Hf the brake pads are not worn and the fluid level is low,
check entire system for leaks {(paga 3-20).
« Do not remove the level float from the reservoir when
filling with brake fluid.
FRONT BRAKE
Turn the handlebar so that the reservoir is level and check
the front brake reservoir fluid level through the sight glass.
If the level is near the lower level mark, remove the cover,
set plate and diaphragm and fill the reservoir with DOT 3 or
4 brake fluid from a sealed container to the casting ledge.
Refer to page 14-3 for brake fluid replacement/bleeding pro-
cedures.
REAR BRAKE
Place the motorcycle on a level surface, and support it
upright. Check the rear brake fluid reservoir level.
lf the lavel is near the lower level mark, remove the reser-
voir cap and fill the reservoir with DOT 3 or 4 brake fluid
from @ sealed container to the upper level mark.
Refer to page 14-3 for brake fluid replacement/bleeding pro-
cedures.
BRAKE PADS WEAR
FRONT BRAKE PAD
Check the brake pads for wear.
Replace the brake pads if the wear limit groove of either
pad is worn out.
Refer to page 14-5 for brake pad replacement.
“LOWER” LEVEL
FRONT: screws —
_ ee
COVER “UPPER” LEVEL
— as
a
SET PLATE
DIAPHRAGM
COVER
SET PLATE _
DIAPHRAGM ~~)
OV Skee LEVEL
FRONT BRAKE CALIPER
3-20
MAINTENANCE
REAR BRAKE PAD
LIMIT GROOVE REAR BRAKE CALIPER
Check the brake pads for wear.
Replace the brake pads if the wear limit groove of either
pad is worn out.
Refer to page 14-7 for brake pad replacement.
BRAKE SYSTEM
INSPECTION FOR AIR IN SYSTEM
Firmly apply the brake lever or pedal, and check that no air
has entered the system. If the lever or pedal feels soft or
spongy when operated, bleed air from the system (page 14-
4).
Remove the step bracket (page 14-24).
Inspect the brake hose and fittings for deterioration, cracks
and signs or leakage. Tighten any loose fittings.
Replace hoses and fittings as required.
Install the step bracket (page 14-24).
BRAKE PEDAL HEIGHT WRRAKE PED aL!
Hi
Remove the step bracket (page 14-24).
Adjust the brake pedal to the desired height.
Loosen the lock nut and turn the push rod to obtain the
peda} height.
Tighten the lock nut after adjustment has been made.
Install the step bracket (page 14-24).
MAINTENANCE
If adjusting the brake pedal to the lower position, make sure
that the clearance between the lower end of the push rod
and the brake pedal does not fall below 1 mm (0.04 in).
If adjusting to the higher position, do not allow the lower
end of the push rod thread to enter into the brake pedal
joint.
BRAKE LIGHT SWITCH
CAUTION:
Allowing the switch body to turn during adjustment can
break the wires in the switch.
NOTE:
* The brake light switch on the front brake lever cannot be
adjusted. If the front brake light switch actuation and
brake engagement are off, either replace the switch unit
or the malfunctioning parts of the system.
* Make all rear brake light switch adjustments after the
height adjustment and the brake pedal free play adjust-
ments have been made.
Remove the step bracket (pgae 14-24).
Check the brake light switch operation and adjustment by
applying the brakes. Visually inspect for any damage and
make sure the reflector plate is clean within the light.
Adjust the rear brake light switch so that the brake light
comes on just prior to the brake actually being engaged. If
the light fails to come on, adjust the switch so that the light
comes on at the proper time.
Turn the adjusting nut on the brake light switch and not the
switch body and wires to make switch actuation adjust-
ments.
NOTE:
Be sure to hold the switch body firmly while turning the
adjusting nut.
After adjustment, recheck to be sure the brake light comes
on at the proper time.
install the step bracket (page 14-241AG).
HEADLIGHT AIM
es
An improperly adjusted headlight may blind oncoming dri-
vers, or it may fall to light the road for a safe distance.
NOTE:
Adjust the headlight beam as specified by local laws and
regulations.
Place the motorcycle on a level surface.
Rotate the adjusting knob and adjust the headlight beam
vertically.
3-22
LOWER POSITION:
BRAKE LIGHT SWITCH
HIGHER POSITION:
rca
CLUTCH SYSTEM
Measure the clutch free play at the end of the clutch lever.
FREE PLAY: 10 - 20 mm (3/8 - 13/16 in}
Adjust as follows:
Minor adjustments ara made at the adjuster near the !ever.
Loosen the lock nut and turn the adjuster. Tighten the lock
nut,
CAUTION:
The adjuster may be damaged if it is positioned too far out,
feaving minimal thread engagement.
If the adjuster is threaded out near its limit and the correct
free play cannot be obtained, turn the adjuster all the way
in and back out one turn.
Tighten the lock nut and make a major adjustment as
dascribed below.
Major adjustments are performed at the clutch arm.
Loosen the lock nut and turn the adjusting nut to adjust free
play. Hold the adjusting nut securely while tightening the
lock nut.
If proper free play cannot be obtained, or the clutch slips
during the test ride, disassemble and inspect the clutch
(refer to saction 8).
ADJUSTER
LOCK NUT
LOCK NUT
MAINTENANCE
ADJUSTING NUT
3-23
MAINTENANCE
SIDE STAND
Support the motorcycle on a level surface.
Check the side stand spring for damage or loss of tansion.
Check the side stand assembly for freedom of movement
and lubricate the side stand pivot tf necessary.
Make sure that the side stand is not bent.
Check the side stand ignition cut-off system:
— Sit astride the motorcycle and raise the side stand.
— Start the engine with the transmission in neutral, then
shift the transmission into gear, with the clutch lever
squeezed.
— Move tha side stand fully down.
— The engine should stop as the side stand is lowered.
Hf there is a problem with the system, check the side stand
switch (section 18).
SUSPENSION
Loose, worn, or damaged suspension parts impair motor-
cycle stability and control. Repair or replace any damaged
components before riding. Riding a motorcycle with faulty
suspension increases your risk of an accident and possible
injury.
FRONT
Check the action of the forks by operating the front brakes
and compressing the front suspension several times.
Check the entire fork assembly for signs of leaks, damage
or
loose fasteners.
Replace damage components which cannot be repaired.
Tighten all nuts and bolts.
Refer to section 12 for front fork service.
3-24
REAR
Support the motorcycle securely using safety stand or hoist
and raise the rear wheel off the ground.
Check for worn swingarm bearings by grabbing the rear
wheel and attempting to move the wheel side to side.
Replace the bearings if any looseness is noted (section 13).
Check the action of the shock absorbers by compressing
them several times.
Check the entire shock absorber assembly for signs of
leaks, damage or loose fasteners.
Replace damaged components which cannot be repaired.
Tighten all nuts and bolts.
Refer to section 13 for shock absorber service.
NUTS, BOLTS, FASTENERS
Check that all chassis nuts, bolts and screws are tightened
to their correct torque values (page 1-13) at the interval
shown in the Maintenance Schedule (page 3-3).
Check that all cotter pins, slip clips, hose clamps and cable
stays are in place and properly secured.
MAINTENANCE
3-25
MAINTENANCE
WHEELS/TIRES
NOTE:
Tire pressure should be checked when the tires are COLD.
RECOMMENDED TIRE PRESSURE AND TIRE SIZE:
REAR
Cold tire
pressure
kPa (kgf/em?,
psi)
Up to 90 kg
(200 Ib) load 200 (2.00, 29) 200 (2.00, 29)
Up to
maximum
weight
capacity
200 (2.00, 29) 225 (2.25, 33)
100/90-1856P | 130/80-17 65P
Bridgestone | TRAIL WING-53G| TRAIL WING-54
PIRELL MT90ST MT90ST
Check the tires for cuts, embedded nails, or other damage.
Check the front and rear wheels for trueness (refer to sec-
tion 12 and 13).
Tire size
Measure the tread depth at the center of the tires.
Replace the tires when the tread depth reaches the follow-
ing limits.
MINIMUM TREAD DEPTH:
FRONT: 0.8 mm (0.03 in)
REAR: 0.8 mm (0.03 in)
STEERING HEAD BEARINGS
NOTE:
Check that the control cables do not interfere with handle-
bar rotation.
Support the motorcycle securely and raise the front wheel
off the ground.
Check that the handlebar moves freely from side to side.
If the handlebar moves unevenly, binds, or has vertical
movement, inspect the steering head bearings (Section 12).
3-26
MEMO
LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM
Ln aecatl
= “F, 1@1
an Se ee | el
i =
ee
4-0
4, LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM 4-0 TROUBLESHOOTING
SERVICE INFORMATION 4-1 OjL PUMP
SERVICE INFORMATION
GENERAL
A WARKING
« Hf the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an
enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and
lead to death. Run the engine in an open area or with an exhaust evacuation system in an enclosed area.
» Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although
this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with
soap and water as soon as possible after handling used oif. KEEP OUT OF REACH OF CHILDREN.
« The ail pump can be serviced with the engine installad in the frame.
* The service procedures in this section must be performed with the engine oil and coolant drained.
* When removing and installing the oil pump, use care not to allow dust or dirt to enter the engine.
* If any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as an assembly.
» After the oil pump has been installed, check that there are no oil leaks.
SPECIFICATIONS
Unit: mm {in}
ITEM STANDARD SERVICE LIMIT
Engine oil capacity | at draining = 1.1 liter (1.2 US qt, 1.0 Imp qt)
at disassembly 1.5 liter (1.6 US qt, 1.3 Imp qt)
at filter change 1.2 liter (1.3 US qt, 1.1 Imp qt}
Recommended engine oil HONDA 4-stroke oil or equivalent motor
oil API service classification SE, SF or
SG Viscosity: SAE 10 W-40
Oil pump rotor | Tip clearance 0.15 (0.006) 0.20 (0.008)
Body clearance 0.15 - 0.21 (0.006 - 0.008} 0.25 (0.010)
Side clearance 0.03 -— 0.11 {0.001 - 0.004) 0.15 (0.006)
LUBRICATION SYSTEM
TORQUE VALUES
Oil pump mounting bolt 14 N-m (1.4 kgf-m, 10 Ibf-ft)
Oil level low Seized engine
« Oil consumption * Noor low oil pressure
« External oil leak « Clogged oil orifice/passage
* Worn piston ring or incorrect piston ring installation * Internal oil leak
« Worn valve guide or seal * Non-recommended oil used
Oil contamination (White appearance) Oil contamination
* From coolant mixing with oil ¢ Deteriorated oil
— Faulty water pump mechanical seal * Faulty oil fitter
— Faulty head gasket ¢ Worn piston ring {White appearance with water or
— Water leak in crankcase moisture)
—— White appearance with water or moisture
No oil pressure ~~ Damaged water pump mechanical seal
« Oil level too low — Damaged head gasket
* Oil pump drive gear broken — Oil relief not frequent enough
* Oil pump damaged (pump shaft)
+ Internal oil leak
Low oil pressure
« Clogged oil filter and strainer screen
* Qil pump worn or damaged
¢ Internal oil leak
* Incorrect oil being used
« Oil level too low
High oii pressure
* Plugged oil filter, gallery, or matering orifice
* Incorrect oif being used
REMOVAL
Drain the engine oil (page 3-10).
Remove the following:
— Right crankcase cover (page 6-13}.
Remove the bolts and oil pump assembly.
Remove the dowel pins.
DISASSEMBLY
Remove the screw and oil pump cover.
Remove the inner and outer rotor from the oil pump body.
COVER SCREW OUTER ROTOR
INSPECTION
Temporarily install the outer and inner rotors into the oil
pump body.
Install the oil pump shaft.
Measure the tip clearance between the inner and outer
rotors.
SERVICE LIMIT: 0.20 mm (0.008 in)
Measure the pump body clearance between the outer
rotor and pump body.
SERVICE LIMIT: 0.25 mm (0.010 in)
LUBRICATION SYSTEM
Measure the side clearance using a straight edge and feeler
gauge.
SERVICE LIMIT: 0.15 mm (0.006 in)
ASSEMBLY
OIL PUMP BODY
OUTER ROTOR
INNER ROTOR
SCREW
OIL PUMP COVER
Install the inner and outer rotors into the oil pump body.
Fill the oil pump with engine oil. a INNER ROTOR
Install the oil pump cover.
OUTER ROTOR COVER
Temporarily install the dowel pins.
Tighten the screw securely.
Remove the dowel pins.
INSTALLATION
Install the dowel pins to the crankcase.
Install the oil pump into the crankcase while aligning the
dowel pins with the holes in the oil pump.
install and tighten the bolts to the specified torque.
TORQUE: 14 N-m (1.4 kgf-m, 10 Ibf-ft)
Install the following:
— Right crankcase cover (page 6-18)
After installation, fill the crankcase with recommended oil
{page 3-10) and fill the coolant (page 6-5).
Check that there is no oil and coolant leak.
DOWEL PINS
LUBRICATION SYSTEM
SCREW
FUEL SYSTEM
5-0
Cu
et CK BS
S$
5, FUEL SYSTEM
SERVICE INFORMATION CARBURETOR ASSEMBLY
TROUBLESHOOTING CARBURETOR COMBINATION
AIR CLEANER HOUSING CARBURETOR INSTALLATION
CARBURETOR BASE CHOKE SYSTEM
CARBURETOR REMOVAL PILOT SCREW ADJUSTMENT
CARBURETOR SEPARATION SECONDARY AIR SUPPLY SYSTEM
CARBURETOR DISASSEMBLY
SERVICE INFORMATION
GENERAL
Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN.
if the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an
enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and
lead to death. Run the engine in an open area or with an exhaust evacuation system in an enclosed araa.
Bending or twisting the control cable will impair smooth operation and could cause the cable to stick or bind,
resulting in loss of vehicle control.
Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can
cause a fire or explosion.
CAUTION:
Be sure to remove the diaphragms before cleaning air and fuel passages with compressed air. The diaphragms might
be damaged.
For fuel tank removal and installation, see page 2-6.
Before disassembling the carburetors, place an approved fuel container under the float chambers, loasen the drain
screws and drain the carburetors.
After removing the carburetors, cover the intake ports of the cylinder heads with shop towels to prevent any foreign
material from dropping into the engine.
When disassembling the fuel system parts, note the locations of the O-rings. Replace them with new ones on
reassembly.
The vacuum chamber and float chamber can be serviced with the carburetors combined.
For carburetor synchronization, see page 3-12.
FUEL SYSTEM
SPECIFICATIONS
ITEM SPECIFICATIONS
Carburetor identification number
VPU 2A
Main jet
Slow jet
Jet needle number
Pilot screw
Front
Rear
Front
# 82
Rear
Initial/fina] opening
# 88
C12A
C12B
See page 5-18
Float level 13.7 mm {0.54 in)
Base carburetor (for synchronization) : Front cylinder (# 2)
Idle speed 1,500 + 100 min* (rpm)
280 mm Hg {11.02 in Hg)
2~6 mm (1/16 — 1/4 in)
PAIR control valve specified vacuum
Throttle grip free play
TORQUE VALUES
Carburetor insulator band screw
PAIR check valve cover bolt
5 N-m (0.5 kgf-m, 3.6 Ibf-ft)
5 N-m (0.5 kgf-m, 3.6 Ibf-ft) Apply loking agent to the threads.
TOOLS
Float level gauge 07401 - 0010000
Pilot screw wrench 07908 ~ 4730002
TROUBLESHOOTING
Engine cranks but won‘t start
a
No fuel in tank
No fuel to carburetor
— Clogged fuel strainer
— Clogged fuel line
Too much fuel getting to the engine
— Clogged air claaner
— Flooded carburetor
Intake air leak
Contaminated/deteriorated fual
Improper choke operation
improper throttle operation
No spark at plug (faulty ignition system-section 16)
Lean mixture
Clogged fuel jets
Faulty float valve
Float level too low
Restricted fuel line
Clogged carburetor air vent tube
Intake air leak
Faulty vacuum piston
Rich mixture
Starting enrichment valve open
Clogged air jets
Faulty float valve
Float lavel too high
Dirty air cleaner
Faulty vacuum piston
FUEL SYSTEM
Engine stalls, hard to start, rough idling
* Restricted fuel line
* Fuel mixture too lean/rich
* Contaminated/deteriorated fue!
* Intake air leak
* Misadjusted idle speed
* Misadjusted pilot screw
* Restricted fuel tank breather tube
« Clogged air cleaner
* Clogged slow circuit
* Starting enrichment valve open
* Faulty ignition system (section 16)
Afterburn when engine braking is used
+ Lean mixture in slow circuit
« Faulty pulse secondary air injection (PAIR) system
— Faulty PAIR control valve
— Faulty PAIR check valve
— Clogged hose of the PAIR system
* Faulty ignition system (section 16)
Backfiring or misfiring during acceleration
« Lean mixture
* Faulty ignition system {section 16}
Poor performance (driveability) and poor fuel economy
* Clogged fuel system
+ Faulty ignition system (section 16)
FUEL SYSTEM
AIR CLEANER HOUSING
REMOVAL/INSTALLATION
Remove the fallowing
— Fuel tank (page 2-8).
— Air cleaner housing cover and element (page 3-6).
Disconnect the crankcase breather hose.
Remove the screws and air cleaner housing.
AIR CLEANER HOUSING SCREWS
CARBURETOR BASE
REMOVAL/INSTALLATION
NOTE:
Do not remove the carburetor base from the carburetors
unless the carburetor overhaul is required.
Disconnect the air supply hose.
AIR SUPPLY
HOSE
FUEL SYSTEM
Unstake the stay edges.
STAY EDGES
CAUTION:
Do not damage the stay.
Remove the eight screws.
Remove the air ducts, stays and carburetor base.
CARBURETOR BASE AIR DUCTS
Remove the fannels and O-rings from the carburetors.
Install the new O-rings to the carburetor grooves.
Install the ramoved parts in the revers order of removal.
FUEL SYSTEM
CARBURETOR REMOVAL
Drain the coolant (page 6-5).
Remove the carburetor base (page 5-4).
Remove the SE valve knob and throttle stop screw control
knob from the stay.
SE VALVE KNOB
THROTTLE STOP SCREW CONTROL KNOB
Loosen the adjusters and remove the throttle cables from
the throttte drum. . ADJUSTERS
Remove the watar hose from the rear cylinder.
Remove the starting enrichment (SE) valve cable from the
clamp.
SE VALVE CABLE
5-6
FUEL SYSTEM
Remove the air tube from the secondary air injection (PAIR)
control valve. PAIR CONTROL VALVE
=a
MWS wes.
‘ rex
At x
Loosen the carburetor insulator band screw of the front
side.
Loosen the carburetor insulator band screw of the rear side.
Remove the carburetors as assembly.
CARBURETOR SEPARATION AIR VENT TUBES
SE VALVE
Remove the following from the front carburetor.
— Starting enrichment (SE) valve
— Water hose
— Fuel drain tube
Air vent tubes from the joint.
WATER HOSE
FUEL SYSTEM
Remove the following from the rear carburetor.
DRAIN TUBE AIR TUBE
— Starting enrichment (SE) valve
— Air tube
— Water hoses
— Fuel drain tube
SE VALVE
Remove the fuel tubes.
FUEL TUBES
Remove the air vent tubes.
AIR VENT TUBES
Remove the cotter pin, washers and disconnect the throttle
link. NUTS/SHAFTS NUT/CLAMP
Remove the nut and clamp.
Remove the nuts, plates, shafts and separate the carbure-
tors.
THROTTLE LINK |= COTTER PIN/WASHERS
FUEL SYSTEM
CARBURETOR DISASSEMBLY
NOTE:
* Each (front/rear) jet needle has an identification mark.
* If you disassemble the both carburetors, keep those
parts separately.
JOINT PIPE
VACUUM CHAMBER
Remove the air vent tube joint pipe.
Remove the three screws and the vacuum chamber cover.
SCREWS
COVER
Remove the compression spring and diaphragm/vacuum
piston from the carburetor body. SPRING
DIAPHRAGM VACUUM PISTON §&
Remove the washer and O-ring from the jet needle holder.
Remove the spring, jet needle and washer from the vacuum
piston.
WASHER
Check the jet needle for stepped wear.
Check the vacuum piston for wear or damage. JET NEEDLE
Check the diaphragm for pin holes, deterioration or dam- at
age.
HOLDER
“ {
DIAPHRAGM/PISTON ine
5-9
FUEL SYSTEM
FLOAT CHAMBER
Remove the throttle stop screw control cable.
Remove the screw and water hose joint.
Remove the three screws and the float chamber.
Remove the float pin, float and float valve.
Check the float for damage or fuel in the float.
Check the float valve and valve seat for scoring, scratches,
clogging or damage.
Check the tip of the float valve, where it contacts the valve
seat, for stepped wear or contamination.
Check the operation of the float valve.
Remove the main jet, needle jet holder and slow jet.
CAUTION:
Handle the jets with care. They can easily be scored or
scratched.
Turn the pilot screw in and carefully count the number of
turns until it seats lightly. Make a note of this to use as a
reference when reinstalling the pilot screw.
CAUTION:
Damage to the pilot screw seat will occur if the pilot screw
is tightened against the seat.
5-10
FLOAT VALVE
MAIN JET
FUEL SYSTEM
Remove the pilot screw, spring, washer and O-ring.
Check each jet for wear or damage.
Check the pilot screw for wear or damage.
Clean the jets with cleaning solvent and blow open with
compressed air.
“*——. PILOT SCREW
CARBURETOR CLEANING
Remove the following:
— diaphragm/vacuum piston
— main jet, needle jet holder and slow jet
— pilot screw
CAUTION:
Cleaning the air and fuel passages with a piece of wire will
damage the carburetor body.
Blow open all air and fuel passages in the carburetor body
with compressed air.
CARBURETOR ASSEMBLY
DIAPHRAGM/VACUUM PISTON FLOAT PIN ~— FLOAT VALVE — THROTTLE STOP SCREW CONTROL KNOB
DRAIN SCREW
JET NEEDLE =e ————
-O@p a,
WASHER amy— \ ROL Fae VE
[KS CT)
SPRING
FLOAT CHAMBER
Ff
FLOAT
NEEDLE JET HOLDER
HOLDER
SLOW JET MAN SET
COMPRESSION PILOT SCREW
VACUUM CHAMBER SPRING JOINT
COVER
5-11
FUEL SYSTEM
FLOAT CHAMBER tee
MAIN JET NEEDLE JET HOLDER
Install the pilot screw and return them to their original posi- be a iD
tion as noted during removal.
Perform the pilot screw adjustment if new pilot screw is
installed.
CAUTION:
Damage to the pilot screw seat will occur if the pilot screw
is tightened against the seat.
Install the needle jet holder, main jet and slow jet.
CAUTION:
Handle the jets with care. They can easily be scored or
scratched.
Hang the float valve onto the float arm lip. : >
Install the float valve, float and float pin. ese fi ad
FLOAT LEVEL INSPECTION
With the float valve seated and the float arm just touching -___ = FLOAT LEVEL GAUGE
the valve, measure the float level with the float level gauge.
TOOL:
Float level gauge 07401 — 0010000
FLOAT LEVEL: 13.7 mm (0.54 in)
The float cannot be adjusted.
Replace the float assembly if the float level is out of specifi-
cation.
Install a new O-ring into the float chamber groove.
Install the float chamber and tighten the three screws.
Install the water joint and tighten the screw securely. oy ines FLOAT CHAMBER
ve Fi
ig ¢
5-12
FUEL SYSTEM
VACUUM CHAMBER
NOTE:
Each (front/rear) jet needle has an identification mark.
If you have disassembled the both carburetors, check the
identification mark of the jet needle as shown to prevent
use the wrong side.
Coat a new O-ring with oil and install it onto the jet needle
holder.
Install the washer onto the jet needle holder,
Install the washer, jet needle, spring and jet needle holder
into the vacuum piston.
Press the jet needle holder until you feel a click indication
that the O-ring is seated the groove in the vacuum piston.
Install the diaphragm/vacuum piston into the carburetor
body.
Life the bottom of the piston with your finger to set the
diaphragm rib in the groove in the carburetor body, and
install the spring and vacuum chamber cover.
Install and tighten the three screws securely.
IDENTIFICATION MARK:
(FRONT) (REAR)
“C12A" "C12B”
WASHER
JET NEEDLE
DIAPHRAGM/PISTON
SCREWS
FUEL SYSTEM
Apply engine oil to the O-ring and install it to the air vent
tube joint.
Install the joint to the carburetor.
CARBURETOR COMBINATION
AIR VENT TUBE
FUEL TUBE
CLAMP
Rie
)
({ 2 ay les
SOG
Bee, EG
Bs
Te —t——— SE VALVE CABLE
THROTTLE LINK
Connect the front and rear carburetors.
oy COTTER PIN/SPACER/WASHERS
=
Install the spacer, throttle link, washers. LINK
Install the new cotter pin securely.
oy COTTER PIN/
mee =SPACER/WASHERS
(REAR)
LINK
(FRONT)
5-14
FUEL SYSTEM
| t :
nstall the plates and shaft NUTS/SHAFTS ere ae
Install the nuts securely.
Install the clamp and tighten the nut securely.
Install the air vent tubes.
AIR VENT TUBES
Install the fuel tubes.
FUEL TUBES
Install the following to the rear carburetor.
DRAIN TUBE AIR TUBE
— Fuel drain tube
— Water hoses
— Air tube
— Starting enrichment (SE) valve
WATER HOSES SE VALVE
5-15
ae
FUEL SYSTEM
Install the following to the front carburetor.
AIR VENT TUBES
— Fuel drain tube SE VALVE
— Water hose
— Starting enrichment (SE) valve
Connect the air vent tubes to the joint.
CARBURETOR INSTALLATION
Connect the carburetors to the front and rear carburetor
insurator.
Tighten the carburetor side insulator band screws so that
the band ends clearance is 0 — 2 mm (0 — 0.08 in).
BAND SCREWS
Connect the air tube to the secondary air injection (PAIR)
control valve. PAIR CONTROL VALVE
AIR TUBE
5-16
FUEL SYSTEM
Install the starting enrichment {SE) valve cable to the
clamp.
ECT SENSOR WIRE
Connect the water hose to the rear cylinder.
install the SE valve knob to the stay.
SE VALVE KNOB
Connect the throttle cables to the throttle drum.
After installation, check the operation of the throttle.
ADJUSTERS
Install the carburetor base (page 5-4).
Fill and bleed the coolant (page 6-5).
FUEL SYSTEM
CHOKE SYSTEM
Remove the carburetors (page 5-7).
Check the starting enrichment (SE) valve for scoring,
scratches or wear.
Check the seat at the tip of the SE valve for stepped wear.
Replace the SE valve set if necessary.
Check the choke cables for frayed, kinked or other damage. SE VALVE
Remove the bolt and replace the choke cable assembly if
necessary.
Install the carburetors (page 5-16).
PILOT SCREW ADJUSTMENT
IDLE DROP PROCEDURE
NOTE:
* Make sure the carburetor synchronization is within speci-
fication before pilot screw adjustment.
« The pilot screws are factory pre-set and no adjustment is
necessary unless the pilot screws are replaced. } PILOT SCREW
* Use a tachometer with graduations of 50 min” (rpm) or Se YQ .
smaller that will accurately indicate a 50 min” (rpm)
change.
=
. Turn each pilot screw clockwise until it seats lightly, then
back it out to the specification given.
This is an initial setting prior to the final pilot screw
adjustment.
CAUTION:
Damage to the pilot screw seat will occur if the pilot screw
is tightened against the seat.
TOOL:
Pilot screw wrench 07908 -— 4730002
INITIAL OPENING: 1 turns out E —\
7 f—> : ‘ei
el aes
PILOT SCREW WRENCH
5-18
FUEL SYSTEM
2. Warm up the engine to operating temperature. Stop and
go driving for 10 minutes is sufficient.
3. Stop the engine and connect a tachometer according to
the tachometer manufacturer's instructions.
4. Start the engine and adjust the idle speed with the throt-
tle stop screw.
IDEL SPEED: 1,500 + 100 min” (rpm)
5. Turn the front carburetor pilot screw in or out slowly to St & DAS
obtain the highest engine speed. ye 03
6. Perform step 5 for rear carburetor pilot screw.
7. Lightly open the throttle 2 or 3 times, then adjust the idle
speed with the throttle stop screw.
8. Turn the front carburetor pilot screw in unti! the engine
speed drops by 50 min’ (rpm}.
9. Turn the rear carburetor pilot screw out to the final open-
ing from the position obtained in step 8.
THROTTLE STOP SCREW CONTROL KNOB
FINAL OPENING:
Front/Rear: 3/4 turns out
10. Adjust the idle speed with the throttle stop screw control
knob.
11. Perform steps 8, 9 and 10 for the rear carburetor pilot
screw.
SECONDARY AIR SUPPLY SYSTEM
SYSTEM INSPECTION
Start the engine and warm it up to normal operating tem-
perature. ;
Remove the air cleaner element (page 3-6}.
Check that the secondary air intake port is clean and free of
carbon deposits.
Check the pulse secondary air injection (PAIR) check valves
if the port is carbon fouled.
INTAKE PORT
FUEL SYSTEM
Disconnect the PAIR control valve vacuum tube from the 3-
way vacuum joint and plug the vacuum joint.
Connect a vacuum pump to the PAIR control valve vacuum
tube,
Start the engine and open the throttle slightly to be certain
that air is sucked in through the air supply hose.
If the air is not drawn in, check the air supply hoses for
clogging.
With the engine running, gradually apply vacuum to the
PAIR control valve vacuum tube.
Check that the air supply hose stops drawing air, and that
the vacuum does not bleed.
SPECIFIED VACUUM: 280 mm Hg (11.02 in Hg)
If the air is drawn in, or if the specified vacuum is not main-
tained, install a new PAIR control valve. If afterburn occurs
on deceleration, even when the secondary air supply sys-
tem is normal, check the air cut-off valve.
PAIR CHECK VALVE INSPECTION
For the rear cylinder PAIR check valve removal, remove the CHECK VALVE
fuel tank (page 2-8). i oe
Remove the bolts, PAIR check valve cover and PAIR check [emma Lg
valve from the cylinder head cover. y ; ts
Check the reed for damage or fatigue. Replace if necessary.
Replace the PAIR check valve if the seat rubber is cracked,
deteriorated or damaged, or if there is clearance between
the reed and seat.
Install the PAIR check valve and cover onto the cylinder
head cover.
Install and tighten the bolts to the specified torque.
TORQUE: 5 N-m (0.5 kgf-m, 3.6 Ibf-ft)
: i aes
| CHECK VALVE |
Bese: neem
5-20
MEMO
SYSTEM FLOW PATTERN
COOLING SYSTEM
GY
ww,
we
a
— MA ~ ;
si AS. RAR A 1 =
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= =,
Ow « I<
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2 Gy \a lo
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6-0
Oy
6. COOLING SYSTEM
SYSTEM FLOW PATTERN THERMOSTAT
SERVICE INFORMATION RADIATOR/COOLING FAN
TROUBLESHOOTING RADIATOR RESERVE TANK
SYSTEM TESTING WATER PUMP
COOLANT REPLACEMENT
SERVICE INFORMATION
GENERAL
A WARNING
* Wait until the engine is cool before slowly removing the radiator cap. Removing the cap while the engine is hot and
the coolant is under pressure may cause serious scaiding.
¢ Radiator coolant is toxic. Keep it away from eyes, mouth, skin and clothes.
— if any coolant gets in your eyes, rinse them with water and consult a doctor immediately.
— if any coolant is swalfowed, induce vomiting, gargle and consult a physician immediately.
— if any coolant gets on your skin or clothes, rinse thoroughly with plenty of water.
* KEEP OUT OF REACH OF CHILDREN.
CAUTION:
Using Coolant with silicate inhibitors may cause premature wear of water pump seals or blockage of radiator pas-
sages.
Using tap water may cause engine damage.
¢« Add coolant at the reserve tank. Do not remove the radiator cap except to refill or drain the system.
¢ Allcooling system services can be done with the engine in the frame.
« Avoid spilling coclant on paintad surfaces.
« After servicing the system, check for leaks with a cooling system tester.
+ Refer to Section 18 for fan motor switch and thermosensor inspection.
SPECIFICATIONS
SPECIFICATIONS
Coolant capacity Radiator and engine 1.03 liter {1.08 US qt, 0.95 Imp qt)
Reserve tank 0.24 liter {0.25 US gt, 0.21 Imp qt)
Radiator cap relief pressure 108 kPa (1.1 kgf/cm’, 16 psi)
Thermostat Begin to open 81 - 84°C (178 - 183°F)
Fully open 95°C (203°F}
Valve lift 4.5 mm {0.18 in) minimum
Standard coolant concentration 50% mixture with soft water
COOLING SYSTEM
TORQUE VALUES
Water pump drain bolt 13 N-m (4.3 kgf-m, 9 Ibf-ft)
Water pump impeller 12 N-m (1.2 kgf-m, 9 Ibf-ft)
Cooling fan nut 1 N-m (0.1 kgf-m, 0.7 Ibf-ft)
TOOLS
Bearing remover head 07936 - GE002060
Bearing remover shaft 07936 - GE00160
Bearing remover weight 07741 - 0010201
Drivar 07749 — 0010000
Attachment, 24 x 26 mm 07746 — 0010700
Attachment, 32 x 35 mm 07746 — 0010100
Pilot, 10 mm 07746 — 0040100
Mechanical seal driver attachment 07945 — 4150400
TROUBLESHOOTING
Engine temperature too high
« Faulty temperature indicator or thermo switch {Section 18)
+ Faulty radiator cap
+ insufficient coolant
« Passages blocked in radiator, hoses or water jacket
« Airinsystem
« Faulty water pump
¢ Thermostat stuck closed
¢ Faulty cooling fan motor
¢ Faulty fan motor switch
Engine temperature too low
* Faulty temperature indicator or thermo switch (Section 18)
* Thermostat stuck open
* Faulty cooling fan motor switch
Coolant leaks
« Faulty water pump mechanical seal
* Deteriorated O-ring
« Damaged or deteriorated gasket
¢ Loose hose connection or clamp
* Damaged or deteriorated hose
* Faulty radiator cap
COOLING SYSTEM
SYSTEM TESTING
COOLANT (HYDROMETER TEST)
x
Be sure the engine is cool before removing the cap or you
may be severely scalded.
Remove the screw from the radiator cap.
Remove the radiator cap.
Check the coolant gravity using a hydrometer.
STANDARD COOLANT CONCENTRATION: 50%
Look for contamination and replace the coolant if neces-
sary.
HYDROMETER
Coolant gravity chart
Coolant temperature °C (°F)
Coolant ratio %
5
15 1.028 ;
a0 ae cas | 036 Ya.059°] 4.081 | a.030 | 1.007 | 1.005 | 1.008 | 1.00t | 1010 |
30 1.053 | 1.052 | 1.051 | 1.049 :
7.072 [7.070 [1.068 | 3.066 | 7.066 | 9.062 | 4.059 | 1.056 | 1.068 |
1.080 | 1.078 | 1.076 | 1.074 | 1.072 | 1.069 | 1.066 | 1.063 | 1.060 | 1.057 | 1.054
ee
ees
p80 | 1.0886 | 1.084 | 1.082 | 1.080 | 1.077 | 7.074 | 1.074 | 1.068 | 1.065 | 1.062 | 1.059
ae
a
1,095 | 1.093 | 1.091 | 1.088 | 1.085 | 1.082 | 1.079 | 1.076 | 1.073 | 1.070 | 1.067
00 | 1098 096 [082 | .08e [ 086 | 08s | 1080 [077 [076 | 071
COOLING SYSTEM
RADIATOR CAP/SYSTEM PRESSURE
INSPECTION
Pressure test the radiator cap using the tester.
Replace the radiator cap if it does not hold pressure, or if
relief pressure is too high or too low, it must hold specified
pressure for at least 6 seconds.
RADIATOR CAP RELIEF PRESSURE:
108 kPa (1.1 kgf/cm?, 16 psi)
Pressure the radiator, engine and hoses using the tester,
and check for leaks.
CAUTION:
Excessive pressure can damage the cooling system compo-
nents. Do not exceed 137 kPa (1.4 kgf/cm’, 20 psi)
Repair or replace components if the system will not hold
specified pressure for at least 6 seconds.
COOLANT REPLACEMENT
PREPARATION
wien
* Radiator coolant is toxic. Keep it away from eyes,
mouth, skin and clothes.
—If any coolant gets in your eyes, rinse them with
water and consult a doctor immediately.
—lIf any coolant is swallowed, induce vomiting, gargle
and consult a physician immediately.
—If any coolant gets on your skin or clothes, rinse thor-
oughly with plenty of water.
* KEEP OUT OF REACH OF CHILDREN.
CAUTION:
Using coolant with silicate inhibitors may cause premature
wear of water pump seals or blockage of radiator passage.
Using tap water may cause engine damage.
NOTE:
* The effectiveness of coolant decreases with the accumu-
lation of rust or if there is a change in the mixing propor-
tion during usage. Therefore, for best performance
change the coolant regularly as specified in the mainte-
nance schedule.
+ Mix only distilled, low mineral water with the antifreeze.
RECOMMENDED MIXTURE:
50 - 50 (Distilled water and antifreeze)
TESTER fae
(ETHYLENE GLYCOL
LOW MINERAL OR
DISTILLED WATER
BASE SOLUTION)
COOLANT
6-4
COOLING SYSTEM
REPLACEMENT/AIR BLEEDING
Eee eee
The engine must be cool before servicing the cooling sys-
tem, or severe scalding may result.
RADIATOR CAP
NOTE:
When filling the system or reserve tank with a coolant
(checking the coolant level), place the motorcycle upright
on a flat, level surface.
Remove the radiator cap.
Remove the drain bolt on the water pump and drain the
coolant from the system.
Remove the water tube and drain the coolant from the
cylinder.
Remove the reserve tank cap.
Disconnect the siphon tube and drain the coolant from the
reserve tank.
Connect the siphon tube and install the drain bolts with
new sealing washers.
RESERVE TAN # 4
5 K SOME SIPHON TUBE §
6-5
COOLING SYSTEM
Fill the system with the recommended coolant through the
filler opening up to filler neck.
Remove the reserve tank cap and fill the reserve tank to the
upper level line.
Bleed air from the system as follows:
1. Shift the transmission into neutral.
Start the engine and let it idle for 2-3 minutes.
2. Snap the throttle 3 —- 4 times to bleed air from the sys-
tem.
3. Stop the engine and add coolant up to the filler neck.
Reinstall the radiator cap.
4. Check the level of coolant in the reserve tank and fill to
the upper level if it is low.
THERMOSTAT
REMOVAL
Drain the coolant (page 6-5).
Remove the thermostat housing cover bolts and cover.
Remove the thermostat from the housing.
NOTE:
The thermostat, may be damaged if dropped or conflicted
to shock.
If dropped or conflicted, inspect the thermostat and replace
if necessary.
INSPECTION
a
* Wear insulated gloves and adequate eye protection.
* Keep flammable materials away from the electric heat-
ing element.
NOTE:
* Do not let the thermostat or thermometer touch the pan,
or you will get false readings.
* Replace the thermostat if valve stays open at room tem-
perature, or if it responds at temperatures other than
those specified.
THERMOSTAT ag
eons \ rae
RADIATOR CAP ©
6-6
COOLING SYSTEM
Visually inspect the thermostat for damage.
Heat the water with an electric heating element to operating
temperature for 5 minutes.
Suspended the thermostat in heated water to check its CA
operation. OG
x
4
AF
THERMOMETER
THERMOSTAT BEGINS TO OPEN:
81 - 84°C (178 - 183°F)
VALVE LIFT:
4. 0.18 i ini
5 mm ( in) minimum THERMOSTAT
INSTALLATION
oy
ms SEAL RUBBER
Apply coolant to the new seal rubber and install to the ther-
mostat flange.
THERMOSTAT
Install the thermostat into the housing cover with aligning
the tab of the seal rubber and cover groove.
Install and tighten the cover bolts securely.
Fill and bleed the cooling system (page 6-5).
COOLING SYSTEM
RADIATOR/COOLING FAN
REMOVAL
SIPHON TUBE
Drain the coolant (page 6-5).
Remove the inner center cowl (page 2-6).
Disconnect the siphon tube.
Remove the fan motor switch connector.
Loosen the hose band screw and disconnect the upper radi-
ator hose.
Loosen the hose band screw and disconnect lower radiator
hose.
Remove the radiator mounting bolts, washers.
Slide and remove the radiator from the stay.
Remove the fan motor 3P connector.
6-8
DISASSEMBLY
Remove the fan motor switch.
Remove the screw and radiator cap.
Remove the bolts and ground terminal.
Remove the cooling fan assembly from the radiator.
Remove the nut and cooling fan.
Remove the motor wires from the clamp.
Remove the screws and washers.
Remove the fan motor from the shroud.
COOLING SYSTEM
RADIATOR CAP
FAN MOTOR SWITCH
fo
COOLING FAN ASSEMBLY
COOLING FAN
FAN MOTOR SCREWS/WASHERS
CLAMP Saar SHROUD
6-9
COOLING SYSTEM
RADIATOR
1 N-m (0.1 kgf-m, 0.7 Ibf-ft)
FAN MOTOR
G
Ay
~ FAN
Reng O-RING
FAN SHROUD FAN MOTOR SWITCH
f h d.
Install the fan motor to the shrou FAN MOTOR SCREWS/WASHERS
Install and tighten the washers/screws securely.
Install the motor wires to the clamp.
SHROUD
Apply locking agent to the motor shaft threads.
yy COOLING FAN
Install the cooling fan onto the motor shaft by aligning the
flat surfaces.
6-10
Install and tighten the nut to the specified torque.
TORQUE: 1 N-m (0.1 kgf-m, 0.7 Ibf-ft)
install the cooling fan assembly to the radiator.
Install and tighten the bolts with the ground terminal.
Install the fan motor switch (page 18-12).
Install the radiator cap.
COOLING SYSTEM
COOLING FAN ASSEMBLY
Re
BOLT/TERMINAL
RADIATOR CAP
uy.
FAN MOTOR SWITCH
6-11
COOLING SYSTEM
INSTALLATION
3P CONNECTOR
Connect the fan motor 3P connector.
Install the radiator to the stay.
Install the washer, radiator mounting bolts and tighten the
mounting bolts securely.
Install the lower radiator hose and tighten the band screw
securely.
Install the upper radiator hose and tighten the band screw
securely.
BAND SCREW
Connect the fan motor switch connector.
Connect the siphon tube.
Fill and bleed the coolant (page 6-5).
Install the inner center cowl (page 2-6).
FAN MOTOR SWITCH CONNECTOR
6-12
COOLING SYSTEM
RADIATOR RESERVE TANK
REMOVAL/INSTALLATION
Remove the front cowl (page 2-4).
Drain the coolant from the reserve tank (page 6-5).
Remove the siphon tube and over flow tube.
Remove the radiator reserve tank.
Installation is in the reverse order of removal.
NOTE: ity V/ We Ss
Route the tubes properly (page 1-23). RESERVE TANK SIPHON TUBE }
Fill the reserve tank with recommended coolant to the
upper level line (page 6-5).
WATER PUMP WATER PUMP COVER
MECHANICAL SEAL INSPECTION “
Check the inspection hole for signs of coolant leakage. If
there is leakage, the mechanical seal is defective and
replace the water pump as an assembly.
REMOVAL
RIGHT CRANKCASE COVER REMOVAL
Drain the coolant (page 6-5).
Drain the engine oil (page 3-10).
Remove the brake pedal and arm (page 14-24).
Remove the two bolts and clutch cable stay.
Disconnect the clutch cable from the lifter arm.
Remove the three bolts and water pump cover.
WA
COOLING SYSTEM
Remove the O-ring from the water pump cover.
- DOWEL PIN
Remove the dowel pin from the right crankcase cover. * a eens?
CAUTION:
Do not remove the inpeller with the right crankcase cover
on the crankcase (see page 6-15 the removal of the
impeller).
Remove the bolt and water hose. = aS oY “ et ma
: é 4 BOLT/WATER HOSE
Remove the right crankcase cover bolts. =.
The clutch lifter arm spindle inside the right crankcase
cover is engaged at the lifter piece.
Carefully remove the right crankcase cover while turning LIFTER PIECE
the clutch lifter arm counterclockwise to disengage the lifter
arm spindle from the lifter piece, then remove the right
crankcase cover.
LIFTER ARM
Remove the gasket and dowel pins.
6-14
COOLING SYSTEM
DISASSEMBLY
Remove the snap ring from the water/oil pump shaft.
Remove the pin and water/oil pump gear.
SNAP RING
Hold the water/oil pump shaft and remove the impeller,
washer and then, remove the water/oil pump shaft from the
right crankcase cover.
Remove the water/oil pump shaft bearing from the right
crankcase cover using the special tools.
TOOLS:
Remover head 07936 —- GE00200
Remover shaft 07936 — GE00100
Remover weight 07741 - 0010201
Remove the oil seal from the right crankcase cover. , "9
Remove the mechanical seal from the right crankcase
cover.
SHAFT
COOLING SYSTEM
ASSEMBLY
BEARING
SHAFT
12 N-m (1.2 kgf-m, 9 Ibf-ft)
Rg
=
OIL SEAL
WATER/OIL PUMP GEAR
MECHANICAL SEAL
WASHER RIGHT CRANKCASE COVER
Apply grease to a new oil seal lip and install the oil seal into
the right crankcase cover using the special tools. DRIVER
TOOLS:
Driver 07749 -— 0010000
Attachment, 32 x 35 mm 07746 - 0010100
ATTACHMENT
Apply sealant to the new mechanical seal flange and drive
it into the right crankcase cover using the special tools.
DRIVER
TOOLS:
Driver 07749 -— 0010000
Mechanical seal driver
attachment 07945 — 4150400
6-16
COOLING SYSTEM
Drive in a new water/oil pump shaft bearing using the spe-
cial tools. DRIVER
TOOLS:
Driver 07949 — 0010000
Attachment, 24 x 26 mm 07746 — 0010700
Pilot, 10 mm 07746 -— 0040100
, ATTACHMENT
Pe,
S BEARING
Check the water/oil pump shaft for damage.
Check the water/oil pump gear for damage of the teeth.
Install the water/oil pump shaft to the right crankcase cover.
6-17
COOLING SYSTEM
Check the water seal for damage and replace if necessary.
WASHER
Install the washer and impeller to the shaft.
IMPELLER = WATER SEAL
Hold the water/oil pump shaft and tighten the impeller to
the specified torque.
TORQUE: 12 N-m (1.2 kgf-m, 9 Ibf-ft)
_ IMPELLER/WASHER/GEAR SHAFT
Install the pin to the water/oil pump shaft.
Install the water/oil pump gear to the shaft with aligning the GEAR GROOVE
pin and gear groove.
Install the snap ring to the water/oil pump shaft groove
securely.
SNAP RING
INSTALLATION
RIGHT CRANKCASE COVER INSTALLATION
Install a new gasket and dowel pins.
6-18
COOLING SYSTEM
Set the right crankcase cover on to the right crankcase
while turning the impeller to engage the flat surface of the
water/oil pump gear shaft with the oil pump inner rotor and
water/oil pump gear with the primary drive gear.
IVE GEAR Be
’ a
€
= PUMP GEAR
Install the right crankcase cover on to the right crankcase
while turning the clutch lifter arm clockwise to engage the LIFTER PIECE
cutout in the lifter arm spindle with the lifter piece flange.
Install and tighten the right crankcase cover bolts securely.
Apply coolant to a new O-ring and install it to the water
hose,
Connect the water hose to the right crankcase cover and
tighten the bolt securely.
Install the dowel pin to the right crankcase cover. Apply
coolant to a new O-ring and install it to the water pump
cover groove.
| Each PIN
6-19
COOLING SYSTEM
Install and tighten the water pump cover bolts securely.
Connect the clutch cable to the lifter arm.
Install the clutch cable stay and tighten the two bolts
securely.
Install the following.
— Brake pedal and arm (page 14-25).
— Right front cover (page 3-13).
Fill and bleed the coolant (page 6-5).
Fill the engine oil (page 3-11).
WATER PUMP COVER
6-20
MEMO
ENGINE REMOVAL/INSTALLATION
| 12 N-m (1.2 kgf-m, 9 Ibf-ft)
| | 39 N-m (4.0 kgf-m,
29 Ibf-ft)
iS
An Fa
1.
wr
ys
WS Ng
¥@
18 N-m (1.8 ~~
LS) e B
o* 4 |
wiz > 2) = S
FY wo 7 ¥)
kgf-m, 13 Ibf-ft) es ; , \
On (cr y z & VA
é x hes
a>, \)
39 N-m (4.0 kgf-m, 29 Ibf-ft)
7. ENGINE REMOVAL/INSTALLATION
SERVICE INFORMATION 7-1 ENGINE/iNSTALLATION
ENGINE REMOVAL 7-3
SERVICE INFORMATION
GENERAL
A hoist or equivalent is required to support the motorcycle when removing and installing the engine.
A floor jack or other adjustable support is required to support and maneuver the engine.
When removing/installing the engine, tape the frame around the engine beforehand for fame protection.
The following components can be serviced with the engine installed in the frame.
— Alternator (section 15)
— Camshaft (section 9)
— Carburetor (section 5)
— Clutch/gearshift linkage (section 8)
— Cylinder head (section 9)
— Ignition pulse generator (section 16)
— Starter motor/starter clutch (section 17)
— Cylinder/piston (section 10)
— Oil pump (section 4)
The following components require engine removal for service.
— Crankshaft (section 11)
— Shift fork, shift drum (section 11)
— Transmission (section 11)
The following components must be removed before removing the engine.
— Front cowl (section 2)
— Muffler/exhaust pipe (section 2)
— Fuel tank (section 2)
— Spark plug (section 3)
— Oil pipe (section 4)
— Radiator/water hose (section 6)
— Carburetor (section 5)
— Clutch cable (section 8)
— Brake pedal arm (section 14)
— Crankcase breather tube (section 11)
After engine installation, adjust the following.
— Clutch cable (page 3-23)
— Drive chain (page 3-16)
— Throttle cable (page 3-4)
— Engine oil level (page 3-9)
ENGINE REMOVAL/INSTALLATION
SPECIFICATIONS
SPECIFICATIONS
Engine dry weight 40.5 kg (89.29 Ibs)
Engine oil capacity at disassembly | 1.5 liter (1.6 US qt, 1.3 Imp qt)
TORQUE VALUES
Drive sprocket setting plate bolt 12 N-m (1.2 kgf-m, 9 Ibf-ft)
Front engine mounting nut 39 N-m (4.0 kgf-m, 29 Ibf-ft)
Rear upper engine mounting nut 39 N-m (4.0 kgf-m, 29 Ibf-ft)
Rear lower engine mounting nut 39 N-m (4.0 kgf-m, 29 Ibf-ft)
Engine hanger bracket bolts 18 N-m (1.8 kgf-m, 13 Ibf-ft)
7-2
ENGINE REMOVAL/INSTALLATION
ENGINE REMOVAL
DRIVE SPROCKET REMOVAL
NOTE:
Refor to page 7-1 for the parts which must be removed
befor removing the engine.
Remove the bolts and left rear cover.
Remove the terminal nut, wire cramp bolt and starter motor
wire form the starter motor (page 17-4).
Disconnect the following:
— Neutral switch connector (page 18-11).
— Alternator connector (page 15-9).
— Ignition pulse generator connector (page 15-1).
— Engine coolant temprature (ECT) sensor connector (page
16-9).
— thermo switch connector (page 18-14).
Loosen the rear axle nut/washer and adjusting nut. EE aa
s ADJUSTING NUT AXLE NUT/WASHER
/
Loosen the adjusting nut of the left side.
Push the rear wheel forward and make a drive chain slack
fully.
ENGINE REMOVAL/INSTALLATION
Remove the gear shift arm pinch bolt and gear shift arm. og
eee a PINCH BOLT
GEAR SHIFT ARM
Remove the bolt and earth cable.
Remove the bolt and chain guide.
Remove the drive sprocket setting plate bolts. f
Remove the setting plate and drive sprocket.
iin Si ~~ oS
CHAIN GUIDE -
REMOVAL
NOTE:
Refer to page 7-1 for the parts which must be removed
before removing the engine.
Place a jack or other adjustable support under the engine.
NOTE:
RThe jack height must be continually adjusted to relieve
stress for ease bolt removal
1. Remove the front engine mounting bolt/nut.
2. Remove the rear upper engine mounting bolt/nut.
3. Remove the engine hanger bracket bolts.
4. Remove the lower engine mounting bolt/nut.
7-4
ENGINE REMOVAL/INSTALLATION
Note the direction of the hanger bolts nuts and plate.
ENGINE INSTALLATION
NOTE:
+ Place the jack or other adjustable support under the
engine.
* The jack height must be continually adjusted to relieve
stress for ease bolt installation.
Place the engine in the frame and all the bolts, nuts, plates
loosely install.
Tighten the all bolts and nuts to the specified torque.
TORQUE:
1. Rear lower engine mounting nut:
39 N-m (4.0 kgf-m, 29 Ibf-ft)
2. Engine hanger bracket bolts: 18 N-m (1.8 kgf-m, 13 Ibf-ft)
3. Rear upper engine mounting nut:
39 N-m (4.0 kgf-m, 29 Ibf-ft)
4. Front engine mounting nut: 39 N-m (4.0 kgf-m, 29 Ibf-ft)
DRIVE SPROCKET INSTALLATION
*EARTH CABLE/
BOLT
Install the bolt and eath cable.
Install the drive sprocket to the countershaft.
Install the drive chain onto the drive sprocket.
Install the setting plate.
Apply locking agent to the threads of the setting plate bolts.
Install and tighten the drive sprocket setting plate bolts.
Install the chain guide and bolts.
ENGINE REMOVAL/INSTALLATION
Install and tighten the drive sprocket setting plate bolts. 4
e PINCH BOLT
Install the gearshift arm. ax ae pe
GEAR SHIFT ARM ~
Connect the following:
— Neutral switch connector (page 18-11).
— Alternator connector (page 15-13).
— Ignition pulse generator connector (page 15-13).
— Engine coolant temperature (ECT) sensor connector
(page 16-9).
— Tharmo switch connector (page 18-14).
Tighten the cover bolts securely.
Install the removed prats (page 7-1).
Adjust the drive chain slack (page 3-16).
coset gt
LEFT REAR COVER ;
7-6
MEMO
CLUTCH/GEARSHIFT LINKAGE
12 N-m (1,2 kgf-m,
9 Ibf-ft)
108 N-m (11 kgf-m, 80 Ibf-ft)
s)
LEY)
8-0
17 Ibf-ft)
- Y
23 N-m (2.3 kgf-m,
12 N-m (1.2 kgf-m,
9 Ibf-ft)
8. CLUTCH/GEARSHIFT LINKAGE
SERVICE INFORMATION 8-1
TROUBLESHOOTING 8-2
CLUTCH
GEARSHIFT LINKAGE
CLUTCH LIFTER ARM REMOVAL/
INSTALLATION 8-3
SERVICE INFORMATION
GENERAL
* The clutch, gearshift linkage parts can be serviced with the engine installed in the frame.
* Engine oil viscosity and level and use of oil additives have an effect on clutch disengagement. Oil additives of any
kind are specifically not recommended. When the clutch does not disengage or the motorcycle creeps with the clutch
disengaged, inspect the engine oil viscosity and level before servicing the clutch system.
* The crankcase must be separated when the transmission, shift drum and shift forks require service (section 11).
* The clutch plates/discs can be serviced without removing the right crankcase cover.
SPECIFICATIONS
Unit: mm (in)
cucherieeay SC=“*‘~*~drC a
B : -0.
eT
20.010 — 20.035 (0.7878 - 0.7888)
D
TORQUE VALUES
Clutch plate warpage
Clutch outer guide L.D.
Clutch center lock nut 108 N-m (11 kgf-m, 80 Ibf-ft) Apply oil to the threads and seating surface
and stake
Clutch pressure plate bolt
Gear shift stopper arm pivot bolt
Gear shift cam plate bolt
TOOLS
Clutch center holder
Gear holder
Driver
Attachment, 28 x 30 mm
Pilot, 12 mm
12 N-m (1.2 kgf-m, 9 Ibf-ft)
12 N-m (1.2 kgf-m, 9 Ibf-ft)
23 N-m (2.3 kgf-m, 17 |bf-ft)
07724 — 0050002
07724 — 0010200
07749 — 0010000
07946 — 1870100
07746 — 0040200
8-1
CLUTCH/GEARSHIFT LINKAGE
TROUBLESHOOTING
Clutch lever too hard
* Damaged, kinked or dirty clutch cable
* Improperly routed clutch cable
¢ Damaged clutch lifter mechanism
* Faulty clutch pressure plate bearing
Clutch will not disengage or motorcycle creeps with clutch disengaged
* Too much clutch lever free play
* Warped plate
* Loose clutch center lock nut
* Improper engine oil viscosity or oil additive used
Clutch slips
* No clutch lever free play
* Clutch lifter sticking
* Worn clutch discs
¢ Weak clutch springs
* Oil additive used
Hard to shift
* Improper clutch operation
* Incorrect engine oil viscosity
* Incorrect clutch adjustment
* Bent or damaged gearshift spindle
* Damaged shift drum grooves
* Bent shift forks or fork shaft (section 11)
Transmission jumps out of gear
« Broken shift drum stopper arm
+ Broken shift linkage return springs
* Damaged shift drum cam grooves
* Bent shift fork shaft (section 11)
* Worn or bent shift forks (section 11)
* Worn gear dogs or slots (section 11)
8-2
CLUTCH/GEARSHIFT LINKAGE
CLUTCH LIFTER ARM REMOVAL/
INSTALLATION
NOTE:
For water pump service operations, refer to section 6.
REMOVAL
Remove the right crankcase cover (page 6-13).
Remove the clutch lifter arm, return spring from the right
crankcase cover.
INSPECTION
Check the dust seal fatigue or damage.
Check the bushing for wear, damage or loose fit.
Replace these parts if necessary.
NOTE:
lf the dust seal replacement is required, press the dust seal
to the case surface.
BUSHING
Remove the snap ring and check the oil seal for wear, dam-
age.
Replace these parts if necessary.
INSTALLATION
Apply engine oil to the clutch lifter arm shaft.
Install the lifter arm into the right crankcase cover.
Install the return spring to the lifter arm.
Hook the spring bottom end in the cover tab and insert the
spring upper end into the lifter arm hole.
Install the right crankcase cover (page 6-18).
RETURN SPRING
RS _ IEE
8-3
CLUTCH/GEARSHIFT LINKAGE
REMOVAL
Remove the right crankcase cover (page 6-13).
Loosen the clutch spring bolts in a crisscross pattern in sev-
eral steps.
Remove the bolts and springs.
Remove the pressure plate.
Remove the lifter piece.
Remove the clutch discs, plates, judder spring, spring seat.
a
R PIECE LS
Unstake the clutch center lock nut.
CAUTION:
Be careful not to damage the mainshaft threads.
Hold the clutch center with the clutch center holder and
loosen the clutch center lock nut.
TOOL:
Clutch center holder 07724 - 0050002
Remove the clutch center lock nut. s s
CLUTCH CENTER HOLDER
Remove the spring washer and washer.
Remove the clutch center.
8-4
CLUTCH/GEARSHIFT LINKAGE
Remove the thrust washer and clutch outer.
\
THRUST WASHER
Remove the clutch outer guide.
INSPECTION
PRESSURE PLATE BEARING
Check the pressure plate bearing for damage.
Turn the bearing inner race with your finger. The bearing
should turn smoothly and quietly without play.
Also check that the bearing outer race fits tightly in the
pressure plate.
Replace if necessary.
BEARING
PRESSURE PLATE BEARING REPLACEMENT
Remove the pressure plate bearing. DRIVER
Drive in a new bearing into the pressure plate.
TOOLS:
Driver 07749 - 0010000 ATTACHMENT
Attachment, 28 x 30 mm 07946 - 1870100
Pilot, 12 mm 07746 — 0040200
8
ms BEARING PILOT
8-5
CLUTCH/GEARSHIFT LINKAGE
CLUTCH SPRING
Measure the clutch spring free length.
SERVICE LIMIT: 41.2 mm (1.62 in)
NOTE:
Replace the clutch springs as a set.
CLUTCH DISC
Check the clutch discs for signs of scoring or discoloration. DISC “B” DISC “A”
Measure the thickness of the discs.
SERVICE LIMITS: Disc A 2.6 mm (0.10 in)
Disc B ==
NOTE:
Replace the discs and plates as a set.
CLUTCH PLATE
Check the plate for excessive warpage or discoloration.
Check the plate warpage on a surface using a feeler gauge.
SERVICE LIMIT: 0.30 mm (0.012 in)
CLUTCH CENTER
Check the clutch center for nicks, indentations or abnormal
wear made by the clutch plates.
CLUTCH OUTER
Check the clutch outer for nicks, indentations or abnormal
wear made by the clutch discs.
Check the serrated teeth of the primary driven gear for wear
or damage.
CLUTCH OUTER GUIDE
Measure the clutch outer guide.
SERVICE LIMITS: I.D.: 20.05 mm (0.789 in)
O.D.: 25.94 mm (1.021 in)
JUDDER SPRING, SPRING SEAT
Check the judder spring and spring seat for distortion, wear
or damage.
MAINSHAFT
Measure the mainshaft O.D. at the clutch outer guide.
SERVICE LIMIT: 19.94 mm (0.785 in)
CLUTCH/GEARSHIFT LINKAGE
CLUTCH CENTER
CLUTCH OUTER
OUTER GUIDE
SPRING SEAT JUDDER SPRING
8-7
CLUTCH/GEARSHIFT LINKAGE
INSTALLATION
Apply molybdenum disulfide oil to the clutch outer guide
and install it to the mainshaft.
Install the clutch outer and thrust washer.
Install the clutch center.
Install the washer.
Install the new spring washer with its “OUT SIDE” mark
facing out.
" MARK =
aera
Apply engine oil to the seating surface of the clutch center
lock nut and install it to the mainshaft.
AU
Hold the clutch center with the clutch center holder and Ae "\
tighten the clutch center lock nut to the specified torque. iy eri
A GES
TOOL:
Clutch center holder 07724 -— 0050002
TORQUE: 108 N-m (11 kgf-m, 80 Ibf-ft)
CLUTCH CENTER HOLDER
8-8
CLUTCH/GEARSHIFT LINKAGE
Stake the clutch center lock nut into the mainshaft.
CAUTION:
Be careful not to damage the mainshaft threads.
Install the spring seat and judder spring on the clutch cen-
ter.
Coat the clutch discs and clutch plate with clean engine oil.
Install the clutch discs and clutch plate as shown.
4: E CLUTCH DISCS “B”
CLUTCH DISCS “A”
CLUTCH CENTER CLUTCH OUTER
SPRING SEAT
a: CLUTCH PLATES
NOTE:
Install the outside clutch disc (A) tabs into the shallow slots
of the clutch outer.
CLUTCH/GEARSHIFT LINKAGE
Apply engine oil to the lifter piece.
Install the lifter piece into the mainshaft.
Install the pressure plate.
Install the clutch springs and clutch spring bolts.
/ PRESSURE PLATE
Tighten the clutch spring bolts to the specified torque in a x y oa
crisscross pattern in several steps.
TORQUE: 12 N-m (1.2 kgf-m, 9 Ibf-ft)
Install the right crankcase cover (page 6-18).
GEARSHIFT LINKAGE Se
REMOVAL “ce ee
Remove the clutch lifter arm (page 8-3).
Remove the clutch (page 8-4).
Remove the gearshift spindle assembly and thrust washer.
plate.
Remove the pin from the shift drum.
Remove the stopper arm bolt, arm, washer and return
spring.
Remove the gearshift cam plate bolt and gearshift cam sort
G
“a
8-10
CLUTCH/GEARSHIFT LINKAGE
INSPECTION genes
Check the gearshift spindle for bending. SPINDLE
Check the spindle plate for wear or damage.
Check the spindle return spring for fatigue or damage.
INSTALLATION
Install the return spring, washer and stopper arm as shown.
Install the pin to the gearshift drum.
Install the washer and stopper arm bolt and tighten the
stopper arm bolt to the specified torque.
TORQUE: 12 N-m (1.2 kgf-m, 9 Ibf-ft)
Hold the stopper arm with the screw driver and install the
gearshift cam plate with aligning the pin and cutout of the
gearshift cam plate.
CLUTCH/GEARSHIFT LINKAGE
Apply locking agent to the gearshift cam plate bolt threads
and tighten the gear shift cam plate bolt to the specified
torque.
TORQUE: 23 N-m (2.3 kgf-m, 17 Ibf-ft)
ae si — =~ Bs IN 8
| THRUST WASHER SPINDLE SHAFT
oa \ a iB
\ i
Apply engine oil to the gearshift spindle shaft.
Install the thrust washer and gearshift spindle assembly.
Install the clutch (page 8-8).
Install the clutch lifter arm (page 8-3).
GEARSHIFT SPINDLE ASSEMBLY
8-12
MEMO
CYLINDER HEAD/VALVES
10 N-m (1.0 kgf-m, 7 Ibf-ft)
12 N-m (1.2 kgf-m,
9 Ibf-ft)
12 N-m (1.2 kgf-m, 9 Ibf-ft)
Si
(ii
>
\A>
SERVICE INFORMATION
TROUBLESHOOTING
CYLINDER COMPRESSION
CYLINDER HEAD SIDE COVER
CYLINDER HEAD COVER REMOVAL
CAMSHAFT REMOVAL
CYLINDER HEAD REMOVAL
SERVICE INFORMATION
GENERAL
tions.
9, CYLINDER HEAD/VALVES
CYLINDER HEAD DISASSEMBLY
VALVE GUIDE REPLACEMENT
VALVE SEAT INSPECTION/REFACING
CYLINDER HEAD ASSEMBLY
CYLINDER HEAD INSTALLATION
CAMSHAFT INSTALLATION
CYLINDER HEAD COVER
INSTALLATION
The front and rear cylinder head cover and front and rear cylinder head can be serviced with the engine in the frame.
The camshaft can be serviced with the engine in the frame.
Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head.
When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original loca-
* Clean all disassembled parts with clean solvent and dry them using compressed air before inspection.
* During assembly apply molybdenum disulfied oil to the camshaft journals of the cylinder head, rocker arm shafts,
rocker arm slipper faces and valve stems to provide initial lubrication.
SPECIFICATIONS
Cylinder compression
Cylinder head warpage
Valve,
valve guide
Valve guide I.D.
Stem-to-guide clearance
Valve guide projection IN
above cylinder head EX
Valve seat width IN/EX
Valve spring free length IN
EX
Camshaft Cam lobe height IN
EX
Runout
Identification marks
Rocker arm shaft O.D. IN/EX
Rocker arm-to-rocker arm shaft clearance
Rocker arm I.D. IN/EX 10.000 - 10.015 (0.3937 — 0.3943) 10.05 (0.396)
Unit: mm (in)
1,304 kPa (13.3 kgf/cm?, 189 psi) at
500 min" (rpm)
0.05 (0.002)
IN 0.15 + 0.02 (0.006 + 0.001) |
EX
0.24 + 0.02 (0.009 + 0.001)
Valve stem O.D. IN 4.975 — 4.990 (0.1959 — 0.1965) 4.965 (0.1955)
EX 4.955 — 4.970 (0.1951 — 0.1957) 4.945 (0.1947)
IN 5.000 — 5.012 (0.1969 — 0.1973) 5.03 (0.198)
EX
5.000 — 5.012 (0.1969 — 0.1973)
0.010 — 0.037 (0.0004 — 0.0015)
| 0.030 — 0.057 (0.0012 — 0.0022)
| 12.10 (0.476)
| 12.10 (0.476)
0.90 — 1.10 (0.035 — 0.043)
5.03 (0.198)
0.065 (0.0026)
0.085 (0.0033)
1.5 (0.06)
38.00 (1.496) 36.5 (1.44)
38.00 (1.496) 36.5 (1.44)
28.8527 — 29.0927 (1.13593 — 1.14538) | 28.82 (1.135)
28.8849 — 29.1249 (1.13720 — 1.14665) | 28.85 (1.136)
0.030 (0.0012) 0.050 (0.0020)
Front “E” /Rear ane
9.972 — 9.987 (0.3926 — 0.3932)
0.013 — 0.043 (0.0005 — 0.0017)
9.92 (0.391)
0.10 (0.004)
CYLINDER HEAD/VALVES
TORQUE VALUES
Cylinder head side cover bolt
Cylinder head cover bolt
Cam sprocket bolt
Camshaft holder bolt
Rocker arm shaft bolt
Cam chain tensioner lifter bolt
Cam chain tensioner lifter plug
Cylinder head 8 mm nut
6 mm nut
TOOLS
Valve guide driver, 5 mm (IN/EX)
Valve spring compressor
Attachment
Valve seat cutter
— Seat cutter IN 24.5 mm (45°)
EX 22 mm (45°)
— Flat cutter IN 25 mm (32°)
EX 22 mm (32°)
— Interior cutter IN/EX 22 mm (60°)
— Cutter holder (IN/EX) 5 mm
Valve guide reamer (IN/EX)
9-2
10 N-m (1.0 kgf-m, 7 Ibf-ft)
10 N-m (1.0 kgf-m, 7 Ibf-ft)
20 N-m (2.0 kgf-m, 14 Ibf-ft) Apply a locking agent to the threads
12 N-m (1.2 kgf-m, 9 Ibf-ft)
5 N-m (0.5 kgf-m, 3.6 Ibf-ft)
12 N-m (1,2 kgf-m, 9 Ibf-ft)
4 N-m (0.4 kgf-m, 2.9 Ibf-ft)
32 N-m (3.3 kgf-m, 24 alll Apply oil to the threads and seating surface
12 N-m (1.2 kgf-m, 9 Ibf-ft)
07942 — MA60000
07757 — 0010000
07959 — KM30101
07780 — 0010100
07780 — 0010701
07780 — 0012000
07780 — 0012601
07780 — 0014202
07781 — 00010400
07984 —- MA60001
TROUBLESHOOTING
CYLINDER HEAD/VALVES
* Engine top-end problems usually affect engine performance. These can be diagnosed by a compression test, or by
tracking noises to the top-end.
* If performance is poor at low speeds, check for white smoke in the crankcase breather tube. If the tube is smoky,
check for a seized piston ring.
Compression too low, hard starting or poor perfor-
mance at low speed
* Valves
— Incorrect valve adjustment
— Burned or bent valves
— Incorrect valve timing
— Broken valve spring
— Uneven valve seating
* Cylinder head
— Leaking or damaged cylinder head gasket
— Warped or cracked cylinder head
* Loose spark plug
* Faulty cylinder, piston (Section 10)
Compression too high
* Excessive carbon build-up in cylinder head or on top
of piston
Excessive smoke
* Worn valve stem or valve guide
* Damaged stem seal
* Faulty cylinder, piston (Section 10)
VALVE TIMING
Excessive noise
Incorrect valve adjustment
Sticking valve or broken valve spring
Damaged or worn camshaft
Loose or worn cam chain
Worn or damaged cam chain tensioner
Worn cam sprocket teeth
Faulty cylinder, piston (section 10)
Rough idle
* Low cylinder compression
TDC OF THE FRONT CYLINDER
COMPRESSION STROKE
TOP DEAD CENTER (TDC)
OF THE REAR CYLINDER
COMPRESSION STROKE
TDC OF THE REAR CYLINDER
90° EXHAUST STROKE
TDC OF THE FRONT CYLINDER
EXHAUST STROKE
CYLINDER HEAD/VALVES
CYLINDER COMPRESSION
I as oe se sai oe ns sat ge
If the engine must be running to do some work, make sure
the area is well-ventilated. Never run the engine in an
enclosed area.
Warm up the engine to normal operating temperature.
Stop the engine, disconnect the spark plug caps and
remove one spark plug at a time.
NOTE:
To measure the cylinder compression of each cylinder,
remove only one plug at a time.
Shift the transmission into neutral.
Install the compression gauge attachment in a spark plug
hole.
Connect the compression gauge to the attachment.
Open the throttle all the way and crank the engine with the
starter motor.
NOTE:
Crank the engine until the gauge reading stops rising. The
maximum reading is usually reached within 4-7 seconds.
STANDARD: 1,304 kPa (13.3 kgf/cm’, 189 psi) at 500 min“
(rpm)
lf compression is high, it indicates that carbon deposits
have accumulated on the combustion chamber and/or the
piston crown.
If compression is low, pour 3 — 5 cc (0.1 — 0.2 oz) of clean
engine oil into the cylinder through the spark plug hole and
recheck the compression.
If the compression increases from the previous value, check
the cylinder, piston and piston rings.
¢ Leaking cylinder head gasket
* Worn piston ring
« Worn cylinder and piston
If compression is the same as the previous value, check the
valves for leakage.
* SPARK PLUG CAP
SPARK PLUG CAP
se \ _
= SPARK PLUG © 4
ae aca sete oe
COMPRESSION GAUGE
2
a — a
CYLINDER HEAD/VALVES
CYLINDER HEAD SIDE COVER
REMOVAL/INSTALLATION
Remove the spark plug cap (page 3-6).
Remove the rubber fillings from the bolts.
Remove the four bolts, washer and cylinder head side cov-
ers.
Installation is in the reverse order of removal. S a We
RUBBER FILLINGS/BOLTS/WASHERS ,
Se REED at CDE
TORQUE:
Cylinder head side cover bolt: 10 N-m (1.0 kgf-m, 7 Ibt-ft)
h-. \
BER FILLINGS/BOLTS/WASHERS
CYLINDER HEAD COVER REMOVAL
FRONT/REAR
NOTE:
The front and rear cylinder head covers can be serviced
with the engine in the frame.
Remove the following:
— Air cleaner housing (page 5-4)
— Cylinder head side cover (page 9-5)
f
BOLTS/WASHERS/RUBBER SEALS |
Remove the air injection hose.
Remove the engine breather hose (Rear side only/page
1-22).
Remove the cylinder head cover bolts, washers and rubber
seals.
Remove the gasket.
GASKET a
ES .
Sack,
Remove the dowel pin and O-ring.
CYLINDER HEAD/VALVES
CAMSHAFT REMOVAL KEEP I NTSNS
TIMING HOLE CAP jaa’
NOTE:
* The camshaft can be serviced with the engine in the
frame.
* The rear cylinder camshaft service procedure is the same
as the front cylinder camshaft service procedure.
Remove the front cylinder head cover (page 9-5).
= CRANKSHAFT HOLE CAP Sagat
Remove the crankshaft hole cap and timing hole cap from
the left crankcase cover.
Remove the camshaft end holder bolts.
Remove the camshaft end holder.
Aig HOLDER (7
Turn the crankshaft counterclockwise and align the “FT”
mark (rear cylinder: “RT” mark) with the index mark on the
left crankcase cover. “ET” MARK
Make sure the front cylinder is at TDC (top dead center).
CYLINDER HEAD/VALVES
Loosen the lifter plug but do not remove yet.
Remove the cam chain tensioner lifter and gasket by
remove the two bolts alternately.
Remove the cam sprocket bolt, turn the crankshaft counter- ae ii il
clockwise 360° degrees and remove the other cam sprocket SPROCKET BOLTS
bolt. 3
Fr ara
ket f th haft fl : —
Remove the cam sprocket from the camshaft flange sur SPROCKETS
face.
Remove the camshaft holder bolts. oe LT am Fas ee
Remove the camshaft holder assembly. “ae SSEMBLY }
Remove the dowel pins.
CYLINDER HEAD/VALVES
Remove the camshaft.
STOPPER PINS
YU
CAM SHA
Remove the cam sprocket from cam chain. | a eaepaemaamerarea ~_ aeee
Attach a piece of mechanic's wire to the cam chain to pre- — : SOCKET
vent it from being dropped into the crankcase. Ee eet
CAMSHAFT HOLDER DISASSEMBLY
NOTE:
The rear cylinder camshaft holder service uses the same
procedure as the front cylinder camshaft holder.
Remove the two bolts.
Remove the rocket arm shafts, rocker arms and wave wash-
HOLDER
ers from the camshaft holder. ROCKER ARMS
WASHERS SHAFTS
CYLINDER HEAD/VALVES
Remove the valve adjuster lock nut and val djusti
sane, eooser ADJUSTING SCREW
LOCK NUT
INSPECTION
CAMSHAFT RUNOUT
Support both ends of the camshaft and check the camshaft
runout with a dial indicator.
Actual runout is 1/2 the total indicator reading.
SERVICE LIMIT: 0.050 mm (0.0020 in)
CAM LOBE HEIGHT
Inspect the cam lobe surfaces for scoring or evidence of
insufficient lubrication.
Measure the height of each cam lobe using a micrometer.
SERVICE LIMITS: IN: 28.82 mm (1.135 in)
EX: 28.85 mm (1.136 in) ©)
NOTE:
Inspect the rocker arm if the cam lobe is worn or damaged.
CAM LOBE
9-9
CYLINDER HEAD/VALVES
ROCKER ARM, ROCKER ARM SHAFT
Inspect the sliding surface of the rocker arms for wear or
damage where they contact the camshaft, or for clogged oil
holes.
Inspect the contact surface of the valve adjuster screw for
wear or damage.
Measure the |.D. of each rocker arm.
SERVICE LIMIT: 10.05 mm (0.396 in)
Measure the each rocker arm shaft O.D.
SERVICE LIMIT: 9.92 mm (0.391 in)
Inspect the shaft for wear or damage and calculate the shaft
to rocker arm clearance.
SERVICE LIMIT: 0.10 mm (0.004 in)
Replace the rocker arm and/or shaft if necessary.
CYLINDER HEAD REMOVAL
NOTE:
* The front and rear cylinder head can be serviced with the
engine in the frame.
* The rear cylinder head service uses the same procedure
as the front cylinder head.
Drain the coolant (page 6-5).
Remove the carburetors (page 5-7).
Remove the camshaft (page 9-6).
Remove the front cylinder to rear cylinder water hose.
Remove the radiator to rear cylinder water hose (Rear side
only).
Remove the bolt and stay. (Front side only).
Remove the thermo switch (Rear side only/page 18-14).
Remove the bolts and nuts.
Remove the cylinder head.
9-10
CYLINDER HEAD/VALVES
Remove the gasket and dowel pins.
CYLINDER HEAD DISASSEMBLY OMPRESSOR
Install the valve spring compressor onto the valve and com-
press the valve spring.
TOOLS:
Valve spring compressor 07757 — 0010000
Attachment 07959 - KM30101
Remove the following:
— Spring retainer VALVE
— Valve springs
—Velve SPRING SEAT
— Stem seal
— Valve spring seat SPRING
— Cotters |
Remove the screw and insulator. COTTERS
= eo STEM SEAL
e
RETAINER
INSPECTION
CYLINDER HEAD
Remove carbon deposits from the combustion chamber.
Check the spark plug hole and valve areas for cracks.
CYLINDER HEAD/VALVES
Check the cylinder head for warpage with a straight edge
and feeler gauge.
SERVICE LIMIT: 0.05 mm (0.002 in)
VALVE SPRING
Measure the free length of the inner and outer valve
springs.
SERVICE LIMIT:
IN: 36.5 mm (1.44 in)
EX: 36.5 mm (1.44 in)
Replace the springs if they are shorter than the service lim-
its.
VALVE
Inspect each valve for benging, burning or abnormal stem
wear.
Check the valve movement in the guide, measure and
record each valve stem O.D.
SERVICE LIMIT:
IN: 4.965 mm (0.1955 in)
EX: 4.945 mm (0.1947 in)
Ream the guides to remove any carbon deposits before
checking clearance.
Insert the reamer from the combustion chamber side of the
head and always rotate the reamer clockwise.
VALVE GUIDE REAMER ~
TOOL:
Valve guide reamer 07984 —- MA60001
9-12
Measure and record each valve guide |.D.
SERVICE LIMIT: IN/EX: 5.03 mm (0.198 in)
Subtract each valve stem O.D. from the corresponding
guide |.D. to obtain the stem-to-guide clearance.
SERVICE LIMITS:
IN: 0.065 mm (0.0026 in)
EX: 0.085 mm (0.0033 in)
If the stem-to-guide clearance is out of specification, dete-
mermine if a new guide with standard dimensions would
bring the clearance within tolerance. If so, replace any
guides as necessary and ream to fit. If the stem-to guide
clearance is out of specification with the new guides,
replace the valves and guides.
VALVE GUIDE REPLACEMENT
Chill the replacement valve guides in the freezer section of
a refrigerator for about an hour.
Heat the cylinder head to 100 — 150°C (212 — 302°F) with a
hot plate or oven.
Ixy ae
To avoid burns, wear heavy gloves when handling the
heated cylinder head.
CAUTION:
Do not use a torch to heat the cylinder head; it may cause
warping.
Support the cylinder head and drive out the valve guides
from combustion chamber side of the cylinder head.
TOOL:
Valve guide driver, 5 mm 07942 - MA60000
Drive in the guide from the top of the head using the spe-
cial tool as shown.
TOOL:
Valve guide driver, 5 mm 07942 - MA60000
CYLINDER HEAD/VALVES
VALVE GUIDE DRIVER
VALVE GUIDE DRIVER
9-13
CYLINDER HEAD/VALVES
NOTE:
Install the valve guide while measuring the valve guide
height from the cylinder head.
SPECIFIED HEIGHT:
IN/EX: 12.10 mm (0.476 in)
Let the cylinder head cool to room temperature.
ra
VALVE GUIDE
Ream the new valve guide after installation. Cc tei aie ai
Insert the reamer from the combustion chamber side of the VALVE GUIDE REAMER
head and also always rotate the reamer clockwise.
TOOL:
Valve guide reamer 07984 —- MA60001
NOTE:
Use cutting oil on the reamer during this operation.
Clean the cylinder head thoroughly to remove any metal
particles,
Reface the valve seat (See below).
VALVE SEAT INSPECTION/REFACING ei HAND-LAPPING TOOL
Clean the intake and exhaust valves thoroughly to remove
carbon deposits.
Apply a light coating of Prussian Blue to the valve seats.
Lap the valves and seats using a rubber hose or other hand-
lapping tool.
Remove and inspect the valve seat face.
CAUTION:
The valves cannot be ground. If a valve face is burned or
badly worn or if it contacts the seat unevenly, replace the
valve.
Inspect the width of each valve seat.
The valve seat contact should be with in the specified width
and even all around the circumference.
STANDARD: 0.90 - 1.10 mm (0.035 — 0.043 in)
SERVICE LIMIT: 1.5 mm (0.06 in)
If the seat is too wide, too narrow or has low spots, the seat
must be ground.
VALVE SEAT
CONTACT WIDTH
CYLINDER HEAD/VALVES
SS
Inspect the valve seat face for:
* Uneven seat width:
— Replace the valve and reface the valve seat.
* Damaged face:
— Replace the valve and reface the valve seat.
* Contact area (too high or too low)
— Reface the valve seat.
NOTE:
The valve cannot be ground. If the valve face is burned or
badly worn or if it contacts the seat unevenly, replace the
valve.
REFACING
NOTE:
* Follow the refacing manufacture’s operating instructions.
* Be careful not to grind the seat more than necessary.
If the contact area is too high on the valve, the seat must be
lowered using a 32° flat cutter.
If the contact area is too low on the valve, the seat must be
raised using a 60° interior cutter.
DAMAGED FACE UNEVEN SEAT
WIDTH
TOO LOW TOO HIGH
45°
60°
32°
CONTACT TOO HIGH
OLD SEAT WIDTH
eal
32°
CONTACT TOO LOW
OLD SEAT WIDTH
=
60°
9-15
CYLINDER HEAD/VALVES
Using a 45° seat cutter, remove any roughness or irregulari-
ties from the seat. ROUGHNESS
TOOLS:
Seat cutter, 24.5 mm (IN) 07780 — 0010100
Seat cutter, 22 mm (EX) 07780 - 0010701
Cutter holder, 5 mm (IN/EX) 07984 —- MA60001
Using a 32° flat cutter, remove 1/4 of the existing valve seat
material.
TOOLS:
Flat cutter, 25 mm (IN) 07780 - 012000 OLD SEAT WIDTH
Flat cutter, 22 mm (EX) 07780 — 0012601
Cutter holder, 5mm 07781 — 0010400
Using a 60° interior cutter, remove 1/4 of the existing valve
seat material.
TOOLS: NN OLD SEAT WIDTH
Interior cutter, 22 mm 07780 — 0014202
Cutter holder, 5mm 07781 — 0010400
Using a 45° seat cutter, cut the seat to the proper width.
SEAT WIDTH
9-16
CYLINDER HEAD/VALVES
After cutting the seat, apply lapping compound to the valve
face, and lap the valve using light pressure. ie HAND-LAPPING TOOL
After lapping, wash all residual compound off the cylinder
head and valve.
CAUTION:
Do not allow lapping compound to enter the guides.
CYLINDER HEAD ASSEMBLY
SPRING RETAINER
VALVE COTTERS
(Z
Ze
VALVE SPRING <P SK
SPRING SEAT
STEM SEAL
VALVE GUIDE
CYLINDER HEAD
EXHAUST VALVE INTAKE VALVE
Clean the cylinder head assembly with solvent and blow
through all oil passages with compressed air. 78 VALVE
Install the valve spring seats. a
Install the new stem seals. mes STEM SEAL
Lubricate the valve stems with engine oil and insert the
valve into the valve guide.
To avoid damage to the stem seal, turn the valve slowly COTTERS > See
SPRING SEAT
“——_ VALVE SPRING
Install the valve spring retainer. s RETAINER
when inserting.
Install the valve springs.
9-17
CYLINDER HEAD/VALVES
Install the valve cotters using the special tool as shown. e COMPRESSOR | .
TOOLS:
Valve spring compressor 07757 — 0010000
Attachment 07959 — KM30101
CAUTION:
To prevent loss of tension, do not compress the valve
spring more than necessary.
ATTACHMENT >
Tap the valve stems gently with two plastic hammers as
shown to seat the cotters firmly.
CAUTION:
Support the cylinder head above the work bench surface to
prevent possible valve damage.
Install the insulator to the inlet manifold with aligning the
insulator groove and lug of the manifold.
Tighten the engine side insulator band screw so that the
band ends clearance is 0 — 2 mm (0 - 0.08 in).
q
Mm
<\
#
BAND SCREWS
9-18
CYLINDER HEAD/VALVES
CYLINDER HEAD INSTALLATION
NOTE:
* Base cylinder is the rear (#1) cylinder.
* If you disassembled the both cylinder heads, install the
rear cylinder head first, then install the front cylinder
head.
* The rear cylinder head uses the same service procedure
as the front cylinder head.
* Be careful not to damage the mating surfaces when
cleaning the cylinder mating surface.
* When cleaning the cylinder mating surface, place the
shop towel over the cylinder opening to prevent dust or
dirt from entering the engine.
Clean any gasket material from the cylinder mating sur-
faces.
Install the new gasket with the “UP” mark is facing up and
dowel pins.
Install the cylinder head.
Apply oil to the cylinder head nut threads and flange sur-
faces.
Tighten the cylinder head nuts to the specified torque.
TORQUE:
8 mm nut: 32 N-m (3.3 kgf-m, 24 Ibf-ft)
6 mm nut: 12 N-m (1.2 kgf-m, 9 Ibf-ft)
NOTE:
* Tighten all hand-tight, then torque the big fasteners
before little fasteners.
* Tighten the bolts and nuts in a crisscross pattern in sev-
eral times.
Lubricate each rocker arm shafts with molybdenum oil
solution.
Install the wave washer, rocker arms and rocker arm shafts
to the camshaft holder.
WAVE
WASHERS
SHAFTS a:
9-19
CYLINDER HEAD/VALVES
Install and tighten the bolts to the specified torque.
TORQUE: 5 N-m (0.5 kgf-m, 3.6 Ibf-ft)
CAMSHAFT INSTALLATION
NOTE:
* If both (front and rear) camshafts are removed, install the
rear cylinder camshaft first, then install the front cylinder
camshaft.
* If the only one side of the cylinder head was serviced,
the other cylinder head cover is required to removal to
check the camshaft position.
INDEX MARK
CAMSHAFT SERVICE FOR BOTH CYLINDER
Remove the timing hole cap (page 3-8).
Turn the crankshaft counterclockwise and align the “RT”
mark on the flywheel with the index mark on the left
crankcase cover, then check the rear cylinder position is
“TDC” (Top Dead Center) of the compression stroke.
Install the rear camshaft (page 9-22).
After install the rear cylinder camshaft, turn the crankshaft
counterclockwise 450° and align the “FT” mark on the fly-
wheel with the index mark on the left crankcase cover, then
install the front camshaft (page 9-22).
INDEX MARK
REAR CYLINDER CAMSHAFT SERVICE ONLY
(FRONT CYLINDER CAMSHAFT WAS NOT SERVICED)
If the front cylinder camshaft was not serviced, remove the
front cylinder head cover (page 9-5) and check the camshaft
position as follows:
Remove the timing hole cap (page 3-8).
Remove the front camshaft end holder (page 9-6)
9-20
“RT” MARK
“FT” MARK
Turn the crankshaft counterclockwise and align the “FT”
mark on the flywheel with the index mark on the left
crankcase cover, then check that the “UP” mark which on
the cam sprocket surface appear and align the timing marks
with the upper surface of the front cylinder head (Front
cylinder position is the TDC/Top Dead Center of the com-
pression stroke).
If the “UP” mark is facing up (TDC/compression stroke),
turn the crankshaft counterclockwise 270° (3/4 revolutions)
and align the “RT” mark on the flywheel with the index
mark on the left crankcase cover, then install the rear
camshaft (see after page).
If the “UP” mark is facing down (TDC/exhaust stroke), turn
the crankshaft counterclockwise 630° (1 3/4 revolutions) and
align the “RT” mark on the flywheel with the index mark on
the left crankcase cover, then install the rear camshaft (see
after page).
FRONT CYLINDER CAMSHAFT SERVICE ONLY
(REAR CYLINDER CAMSHAFT WAS NOT SERVICE)
If the rear cylinder camshaft was not serviced, remove the
rear cylinder head cover (page 9-5) and check the camshaft
position as follows:
Remove the timing hole cap (page 3-8).
Remove the rear camshaft end holder (page 9-6).
Turn the crankshaft counterclockwise and align the “RT”
mark on the flywheel with the index mark on the left
crankcase cover, then check that the “UP” mark which on
the cam sprocket surface appear and align the timing marks
with the upper surface of the rear cylinder head (Rear cylin-
der position is the TDC of the compression stroke.)
If the “UP” mark is facing up (TDC/compression stroke),
turn the crankshaft counterclockwise 450° (1 1/4 revolu-
tions) and align the “FT” mark on the flywheel with the
index mark on the left crankcase cover, then install the front
camshaft (see after page).
If the “UP” mark is facing down (TDC/exhaust stroke), turn
the crankshaft counterclockwise 90° and align the “FT”
mark on the flywheel with the index mark on the left
crankcase cover, then install the front camshaft (see after
Page).
CYLINDER HEAD/VALVES
FRONT:
SIE,
“UP” MARK 44 >
2:
4 TIMING HOLE
TIMING ee
TZ, y “ET” MARK
CYLINDER HEAD INDEX MARK
P” MARK
TIMING HOLE
/ ( “FT” MARK
ie
CYLINDER HEAD INDEX MARK
“UP” MARK
:
TIMING HOLE
S- “RT” ww
INDEX MARK CYLINDER HEAD
TIMING MARK
’
\:
“UP” MARK
TIMING HOLE
“a RT”
ws
INDEX MARK
CYLINDER HEAD
9-21
CYLINDER HEAD/VALVES
CAMSHAFT INSTALLATION
NOTE:
* Base cylinder is the rear (# 1) cylinder.
¢ If you removed the both camshafts, install the rear
camshaft first, then install the front camshaft.
+ The rear camshaft service uses the same procedure as
the front camshaft.
Remove the timing hole cap (page 3-8).
Turn the crankshaft counterclockwise and align the “FT”
mark (rear cylinder: “RT” mark) on the flywheel with the
index mark on the left crankcase cover.
Install the cam sprocket to the cam chain with the “UP”
mark facing the outside and align the timing marks on the
cam sprocket with the upper surface of the cylinder head.
Install the camshaft through the cam chain and cam sprock-
et with the camshaft.
Fill the oil pocket with the engine oil.
“FT” MARK
“RT” MARK
INDEX MARK
aT
“UP” MARK
A TIMING MAR
LE A AOI mB
CAM CHAIN/SPROCKET
9-22
CYLINDER HEAD/VALVES
Install the dowel pins.
Loosen the valve adjusting screw and lock nut fully.
Lubricate each rocker arm slipper surface and valve stem
end with molybdenum oil solution.
2 ROCKER ARM SLIPPER Sa
Sg
Install the camshaft holder assembly.
HOLDER ASSEMBLY ™
Install and tighten the camshaft holder bolts to the specified "===
torque. pees
TORQUE: 12 N-m (1.2 kgf-m, 9 Ibf-ft)
Install the cam sprocket on the camshaft flange and Eee
recheck that the timing marks align with the upper - CAM SPROCKET |
surface of the cylinder head.
Clean and apply a locking agent to the cam sprocket bolt
threads.
Align the cam sprocket bolt holes with the cam sprocket
and camshaft.
Temporarily install the cam sprocket bolt.
Turn the crankshaft counterclockwise 360° and tighten the
other sprocket bolt to the specified torque.
TORQUE: 20 N-m (2.0 kgf-m, 14 Ibf-ft)
Turn the crankshaft counterclockwise 360° and tighten the
other sprocket bolt to the specified torque (see above).
CYLINDER HEAD/VALVES
Remove the tensioner lifter plug.
Check the lifter operation:
— The tensioner shaft should not go into the body when it
is pushed.
— When it is turned clockwise a screwdriver, the tensioner
shaft should be pulled into the body.
The shaft spring out of the body as soon as the screw-
driver is released.
Turn the tensioner shaft clockwise with a screwdriver to
retract the tensioner.
Install a new gasket and tensioner to the cylinder.
Tighten the bolts securely and release the screwdriver.
Install the new O-ring and tighten the lifter plug to the spec-
ified torque.
TORQUE: 4 N-m (0.4 kgf-m, 2.9 Ibf-ft)
NOTE:
Before install the camshaft end holder, adjust and check the
other camshaft position (page 9-20, 21).
Install the camshaft end holder with it’s flat surface on the
holder facing in.
Install and tighten the camshaft end holder bolts to the
specified torque.
TORQUE: 12 N-m (1.2 kgf-m, 9 Ibf-ft)
Adjust the valve clearance (page 3-8).
9-24
ET Sas
-
CYLINDER HEAD/VALVES
Install the thermo switch (Rear side only).
Connect the radiator to rear cylinder water hose (Rear side
only).
Connect the front cylinder to rear cylinder water hose.
Install the stay and tighten the bolt securely.
CYLINDER HEAD COVER INSTALLATION
FRONT/REAR
NOTE:
The front and rear cylinder head cover can be serviced with
the engine in the frame.
Apply engine oil to the new O-ring and install the O-ring to
the dowel pin.
Install the dowel pin to the cylinder head.
Clean the gasket groove of the cylinder head cover. Apply
Honda Bond A or equivalent to the gasket groove of the
cylinder head cover, then install the new gasket into the
groove.
Install the cylinder head cover to the cylinder head.
GASKET
Install the rubber seals, washers and bolt to the cylinder
head cover.
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ER SEAL WASHER ==
_ RUBB
CYLINDER HEAD/VALVES
Tighten the cylinder head cover bolts to the specified
torque.
TORQUE: 10 N-m (1.0 kgf-m, 7 Ibt-ft)
Connect the air injection hose.
Connect the engine breather hose (Rear side only).
Install the following:
— Cylinder head side cover (page 9-5).
— Air cleaner housing (page 5-4).
fs
AIR INJECTION HOSE
9-26
MEMO
CYLINDER/PISTON
12 N-m (1.2 kgf-m, 9 Ibf-ft)
3 N-m (2.3 kgf-m, 17 Ibf-ft)
a /
er
HP
DI ~
co
ese
4 N-m (0.4 kgf-m, 2.9 Ibf-ft)
Ke
10-0
10. CYLINDER/PISTON
SERVICE INFORMATION CRANKCASE STUD BOLT INSPECTION 10-7
TROUBLESHOOTING PISTON INSTALLATION 10-8
CYLINDER REMOVAL CYLINDER INSTALLATION 10-9
PISTON REMOVAL
SERVICE INFORMATION
GENERAL
The engine must be removed from the frame before servicing the cylinder and piston.
Take care not to damage the cylinder wall and piston.
Be careful not to damage the mating surfaces by using a screwdriver when disassembling the cylinder.
Clean all disassembled parts with clean solvent and dry them using compressed air before inspection.
* When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original loca-
tions.
SPECIFICATIONS
Piston, piston | Piston mark direction “IN” mark facing toward the intake
rings side
Piston O.D. 41.97 — 41.99 (1.652 — 1.653)
Piston O.D. measurement point 14.0 (0.55) from bottom of skirt
Piston pin bore |.D. 13.002 — 13.008 (0.5119 - 0.5121) 13.04 (0.513)
Piston pin O.D. 12.994 — 13.000 (0.5116 — 0.5118) 12.98 (0.511)
Piston-to-piston pin clearance 0.002 — 0.014 (0.0001 — 0.0006) 0.04 (0.002)
Piston ring-to-ring p 0.015 — 0.05 (0.0006 — 0.002) 0.080 (0.0031)
Unit: mm (in)
41.90 (1.650)
To -0. :
Second “RN” mark |
Cylinder-to-piston clearance 0.010 — 0.040 (0.0004 — 0.0016)
Connecting rod small end I.D. 13.016 — 13.034 (0.5124 — 0.5131)
0.010 — 0.040 (0.0004 — 0.0016) 0.06 (0.002)
Connecting rod-to-piston pin clearance
10-1
CYLINDER/PISTON
SS SS ann
TROUBLESHOOTING
Compression too low, hard starting or poor performance at low speed
* Leaking cylinder head gasket
¢ Worn, stuck or broken piston rings
* Worn or damaged cylinder and piston
¢ Loose spark plug
Compression too high, over heating or knocking
* Excessive carbon build-up in cylinder head or on top of piston
Abnormal noise
¢« Worn cylinder and piston
« Worn piston pin or piston pin hole
* Worn connecting rod small end
Excessive smoke
* Worn cylinder, piston and piston rings
* Improper installation of piston rings
¢ Scored or scratched piston or cylinder wall
10-2
CYLINDER REMOVAL
NOTE:
* Front and rear cylinders can be serviced with engine in
the frame.
* The front cylinder service uses the same procedure as
the rear cylinder.
Remove the cylinder head (page 9-10).
Remove the two bolts and water hose from the front cylin-
der and water pump (Front side only).
Remove the joint collar clips.
Slide the cylinder joint collar toward the front cylinder.
Remove the cylinder.
Remove the joint collar.
NOTE:
« Attach a piece of mechanic’s wire to the cam chain to
prevent it from being dropped into the crankcase.
* Be careful not to damage the mating surfaces by using a
screwdriver when disassembling the cylinder.
CYLINDER/PISTON
WATER HOSE
Pe
CYLINDER
JOINT COLLAR
10-3
CYLINDER/PISTON
Remove the gasket and dowel pins.
Clean off any gasket material from the cylinder upper sur-
face.
NOTE:
Be careful not to damage the gasket surface.
4 GASKET
Remove the engine coolant temperature (ECT) sensor and san = ‘
sealing washer. SEALING WASHER
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INSPECTION
Inspect the cylinder wall for scratches and wear.
Measure and record the cylinder |.D. at three levels in both
the X and Y axes. Take the maximum reading to determine
the cylinder wear.
SERVICE LIMIT: 42.10 mm (1.657 in)
Calculate the cylinder for out of round at the three levels in
an X and Y axis. Take the maximum reading to determine
the out of round.
SERVICE LIMIT: 0.06 mm (0.002 in)
Calculate the cylinder for taper at three levels in an X and Y
axis. Take the maximum reading to determine the taper.
SERVICE LIMIT: 0.06 mm (0.002 in)
The cylinder must be rebored and an oversize piston fitted
if the service limits are exceeded.
The following oversize pistons are available: 0.25 mm
(0.010 in), 0.50 mm (0.020 in).
The cylinder must be rebored so that the clearance for an
oversize piston is 0.020 — 0.060 mm (0.0008 — 0.0024 in).
10-4
CYLINDER/PISTON
Check the cylinder for warpage by placing a straight edge
and a feeler gauge.
SERVICE LIMIT: 0.05 mm (0.002 in)
PISTON REMOVAL
NOTE:
* Place a shop towel over the crankcase opening to pre-
vent piston pin clips from falling into the crankcase.
* The rear piston service using the same procedure as for
the front piston.
Remove the piston pin clip, piston pin and piston.
Spread each piston ring and remove it by lifting it up at a
point just opposite the gap.
CAUTION:
¢« Do not damage the piston ring by spreading the ends
too far.
* Be careful not to damage the piston when the piston
ring removal.
PISTON RING
een : ce
Clean carbon deposits from the piston.
NOTE:
Clean carbon deposits from the piston ring grooves with a
ring that will be discarded. Never use a wire brush; it will
scratch the grooves.
10-5
CYLINDER/PISTON
INSPECTION
Inspect the piston for cracks or other damage.
Inspect the ring grooves for excessive wear and carbon
build-up.
Measure each piston O.D..
NOTE:
Take measurements 14 mm (0.6 in) from the bottom, and
90° to the piston pin hole.
SERVICE LIMIT: 41.90 mm (1.650 in)
Calculate the piston-to-cylinder clearance. Take the maxi-
mum reading to determine the clearance (Cylinder I.D.:
page 10-4).
SERVICE LIMIT: 0.10 mm (0.004 in)
Measure each piston pin hole |.D. in an X and Y axis.
Take the maximum reading to determine I.D..
SERVICE LIMIT: 13.04 mm (0.513 in)
Measure the piston pin O.D. at three points.
SERVICE LIMIT: 12.98 mm (0.511 in)
Calculate the piston-to-piston pin clearance.
SERVICE LIMIT: 0.04 mm (0.002 in)
Measure the connecting rod small end |.D..
SERVICE LIMIT: 13.044 mm (0.5135 in)
Calculate the connecting rod small end-to-piston pin clear-
ance.
SERVICE LIMIT: 0.06 mm (0.002 in)
10-6
Inspect the piston ring, and replace them if they are worn.
Reinstall the piston rings (page 10-8) into the piston
grooves.
Push in the ring until the outer surface of the piston ring is
nearly flush with the piston and measure the clearance
using a feeler gauge.
SERVICE LIMIT:
Top: 0.080 mm (0.0031 in)
Second: 0.080 mm (0.0031 in)
Using a piston, push the ring securely into the cylinder and
measure the end gap using a feeler gauge.
SERVICE LIMIT:
Top: 0.30 mm (0.012 in)
Second: 0.50 mm (0.020 in)
Oil 0.80 mm (0.031 in)
CRANKCASE STUD BOLT INSPECTION
Check the stud bolts for looseness.
If the stud bolts are loose, remove the stud bolts and apply
engine oil to the threads and tighten the stud bolt securely
or replace the stud bolt and clean and apply a locking agent
to the new stud bolt threads and tighten the stud bolt
securely.
NOTE:
Install the stud bolts with its short thread area side facing to
the cylinder head side.
After installing, be sure to measure the length from the top
of each stud bolt to crankcase surface.
STANDARD LENGTH:
A. 146 mm/MB8, R. Crankcase cover side:
132.4 mm (5.21 in)
B. 146 mm/MB8, Cam chain side:
137.4 mm (5.41 in)
C. 160 mm/M6, L. Crankcase cover side:
145 mm (5.7 in)
CYLINDER/PISTON
STUD BOLT
eho
oo
CYLINDER HEAD SIDE
A: 132.4 mm (5.21 in)
B: 137.4 mm (5.41 in)
C: 145 mm (5.7 in)
Ui
10-7
CYLINDER/PISTON
PISTON INSTALLATION
NOTE:
The rear piston service uses the same procedure as the
front piston.
Clean the piston heads, ring lands and skirts.
Carefully install the piston rings onto the piston with their
markings facing up.
CAUTION:
* Do not damage the piston ring by spreading the ends
too far.
* Be careful not to damage the piston when the piston
ring installation.
NOTE:
* Do not confuse the top and second rings: The top ring is
chrome-coated and second ring is not coated (black).
+ After installing the rings they should rotate freely, with-
out sticking.
* Space the ring end gaps 120 degrees apart.
MARK
PISTON
TOP RING
Ae
ECOND RIN
e/a
SPACER
10-8
PISTON
» PISTON RING
nes Bahco
MARK
TOP RING
SECOND RING
SPACER
PISTON
NOTE:
When cleaning the cylinder mating surface, place a shop
towel over the cylinder opening to prevent dust or dirt enter
the engine.
Clean any gasket material from the cylinder mating sur-
faces of the crankcase.
NOTE:
Place a shop towel over the crankcase opening to prevent
piston pin clips from falling into the crankcase.
Apply molybdenum solution to the piston pin outer sur-
faces.
Apply engine oil to the connecting rod small end and piston
pin hole.
Install the piston with its “IN” mark facing the intake side.
Install the piston pin.
Install the new piston pin clips.
CAUTION:
Always use new piston pin clips. Reinstalling used piston
pin clips may lead to serious engine damage.
NOTE:
* Set the piston pin clip in the groove properly.
* Do not align the clip’s end gap with the piston cut-out.
CYLINDER INSTALLATION
NOTE:
* The rear cylinder service using the same procedure as
for the front cylinder.
When cleaning the cylinder mating surface, place a shop
towel over the cylinder opening to prevent dust or dirt
enter the engine.
Install the dowel pins and new gasket with the “UP” mark
facing up.
CYLINDER/PISTON
10-9
CYLINDER/PISTON
Install a new sealing washer and engine coolant tempera-
ture (ECT) sensor.
Tighten the engine coolant temperature (ECT) sensor to the
specified torque.
TORQUE: 23 N-m (2.3 kgf-m, 17 Ibf-ft)
Apply engine oil to the cylinder wall and piston outer sur-
faces and piston rings.
CAUTION:
Be careful not to damage the piston rings and cylinder
walls.
Apply coolant to the new O-rings and install it to the water
joint collar.
Install the joint collar to the front cylinder.
Route the cam chain through the cylinder.
Install the cylinder over the piston rings by hand while com-
pressing the piston rings.
Slide the cylinder joint collar to the its original position.
Install the joint collar clips to the groove on the water joint.
: oy SEALING WASHER
ENGINE COOLANT
TEMPERATURE SENSOR
CYLINDER
JOINT COLLAR
JOINT COLLAR
10-10
CYLINDER/PISTON
wares
Apply coolant to the new O-rings and install to the water
joint.
Install the water joint to the front cylinder and water pump
(Front side only).
» O-RINGS
Install the water joint bolts.
Tighten the bolts securely (Front side only).
Install the cylinder head (page 9-19).
10-11
CRANKCASE/TRANSMISSION/CRANKSHAFT
11-0
11, CRANKCASE/TRANSMISSION/CRANKSHAFT
SERVICE INFORMATION CRANKSHAFT
TROUBLESHOOTING CRANKCASE BEARING
CRANKCASE SEPARATION REPLACEMENT
TRANSMISSION CRANKCASE ASSEMBLY
SERVICE INFORMATION
GENERAL
* The crankcase must be separated to service the transmission and crankshaft. To service these parts, the engine must
be removed from the frame.
* The following components must be removed before separating the crankcase.
— Oil pump (section 4)
— Clutch, gearshift linkage (section 8)
— Cylinder head (section 9)
— Cylinder and piston (section 10)
— Starter motor, Starter clutch, primary drive gear (section 17)
— Flywheel (section 15)
SPECIFICATIONS
Unit: mm (in)
Transmission | Gear |.D. M4, M5, C1, C2
C3
Bushing 0.
ma
Bushing I.D.
C1 18.000 — 18.018 (0.7087 — 0.7094)
20.000 — 20.021 (0.7874 — 0.7882)
22.000 — 22.021 (0.8661 — 0.8670)
0.020 — 0.062 (0.0008 — 0.0024)
20.04 (0.789)
22.04 (0.868)
M4, M5,
0.10 (0.004)
C1, C2, C3
Mainshaft O.D. M4 bushing 19.959 — 19.980 (0.7858 — 0.7866) 19.94 (0.785)
Countershaft O.D. C1 bushing 17.966 — 17.984 (0.7073 — 0.7080) 17.95 (0.707)
Gear-to-bushing clearance
C2 bushing 19.974 — 19.987 (0.7864 — 0.7869) 19.95 (0.785)
C3 bushing 21.959 — 21.980 (0.8645 — 0.8654) 21.94 (0.864)
0.040 — 0.082 (0.0016 — 0.0032) 0.10 (0.004)
Bushing-to-shaft clearance
C1 0.016 — 0.052 (0.0006 - 0.0020) 0.08 (0.003)
0.013 — 0.047 (0.0005 - 0.0019) 0.08 (0.003)
c3 0.020 - 0.062 (0.0008 - 0.0024) 0.09 (0.004)
Shiftfork [1D ___| 12,000~ 12.018 (0.4724 - 0.4731) 12.03 (0.474)
Claw thickness 4.930 — 5.000 (0.1941 — 0.1969) 4.9 (0.19)
Shift fork shaft O.D. 11.957 — 11.968 (0.4707 — 0.4712) 11.95 (0.470)
Shift drum O.D. (at left side journal) 13.966 — 13.984 (0.5498 — 0.5506) 13.94 (0.549)
Crankshaft Connecting rod big end side clearance 0.05 — 0.70 (0.002 — 0.028) 0.80 (0.031)
Connecting rod big end radial clearance 0.020 (0.0008)
Runout 0.05 (0,002)
11-1
.CRANKCASE/TRANSMISSION/CRANKSHAFT
TORQUE VALUES
Mainshaft bearing setting plate bolt bi | 10 N-m (1.0 kgf-m, 7 Ibf-ft) Apply to locking agent.
Shift drum bearing setting plate bolt
TOOLS
BUniversal bearing puller
Attachment, 32 x 35 mm
Attachment, 42 x 47 mm
Pilot, 17 mm
Pilot, 25 mm
Pilot, 15 mm
Pilot, 20 mm
Driver
Bearing remover set, 15 mm
— bearing remover head
— remover shaft
— remover weight
07631 — 0010000
07746 — 0010100
07746 — 0010300
07746 — 0040400
07746 — 0040600
07746 — 0040300
07746 — 0040500
07749 — 0010000
07936 — KC10000
07936 — KC10100
07936 — KC10200
07411 — 0010201
07PMD — KBP0100
07965 — VM00100
07965 — VM00200
07XMF — KGB0100
07XMF — KGB0200
07XMF — KGB0300
Mechanical seal driver
Crankshaft assembly collar
Crankshaft assembly shaft
Bearing installer 37.42
Bearing installer 37.5
Plate, 200 x 300 x 20
TROUBLESHOOTING
Engine noise
* Worn crankshaft bearing
* Worn connecting rod big end bearing
*« Worn transmission bearing
Transmission jumps out of gear
* Worn gear dogs and slots
* Bent or damaged shift fork
* Bent shift fork shaft
* Damaged shift drum stopper arm
Hard to shift
¢ Clutch not adjusted properly
¢ Bent shift fork
* Bent shift fork shaft
« Worn or damaged shift drum cam grooves
11-2
CRANKCASE/TRANSMISSION/CRANKSHAFT
CRANKCASE SEPARATION
NOTE:
Refer to page 11-1 for the parts which must be removed
before separating the crankcase,
Remove the bolts, washers, collars, cam chain guides and
cam chain tensioners.
ae
BOLTS
Remove the cam chains from the timing sprocket.
TIMING SPROCKET ©
Loosen the left crankcase bolts in a crisscross pattern in 2
Fs
or 3 steps to prevent crankcase distortion. BOLT/SEALING
WASHER
Remove the left crankcase bolts and sealing washers. oe
Place the crankcase with the left side down and remove the
right crankcase.
RIGHT CRANKCASE
CRANKCASE/TRANSMISSION/CRANKSHAFT
Remove the dowel pins.
Clean off the sealant from the right and left crankcase mat-
ing surface.
DOWEL PINS
R the oil i ipe f the right k ;
emove the oil scavenging pipe from the right crankcase Ol, SCAVENGING PIPE
Remove the oil strainer screen.
OIL STRAINER SCREEN
TRANSMISSION
REMOVAL/DISASSEMBLY
Remove the following:
— Shift fork guide shaft
— Shift fork R
— Shift fork C
— Shift fork L
— Shift drum
11-4
CRANKCASE/TRANSMISSION/CRANKSHAFT
Remove the mainshaft and countershaft as an assembly.
Disassemble the mainshaft and countershaft.
COUNTERSHAFT
NOTE:
* Keep track of the disassembled parts (gears, bushings,
washers, and snap rings) by stacking them on a tool or
slipping them onto a piece of wire.
* Do not expand the snap ring more than necessary for
removal. To remove a snap ring, expand the snap ring
and pull it off using the gear behind it.
MAINSHAFT
INSPECTION
GEAR
Check the gear dogs, dog holders and teeth for damage or
excessive wear.
Measure the I.D. of each gears.
SERVICE LIMITS:
M4, M5, C1, C2: 23.04 mm (0.907 in)
C3: 25.06 mm (0.987 in)
BUSHING
Check the bushings for damage or excessive wear.
Measure the O.D. of each bushings.
SERVICE LIMITS: Seairt
M4, M5, C1, C2: 22.94 mm (0.903 in)
C3: 24.96 mm (0.983 in) ——$—
Measure the |.D. of each bushings.
SERVICE LIMITS:
M4: 20.06 mm (0.790 in)
C1: 18.04 mm (0.710 in)
C2: 20.04 mm (0.789 in)
C3: 22.04 mm (0.868 in)
11-5
CRANKCASE/TRANSMISSION/CRANKSHAFT
MAINSHAFT/COUNTERSHAFT
oo MAINSHAFT sha
Check the spline grooves and sliding surfaces for damage = |
or abnormal wear.
Measure the O.D. of the mainshaft and countershaft at the ms
gear and bushing sliding areas.
SERVICE LIMITS:
Mainshaft:
M4 gear bushing: 19.94 mm (0.785 in)
Countershaft:
C1 gear bushing: 17.95 mm (0.707 in)
C2 gear bushing: 19.95 mm (0.785 in)
C3 gear bushing: 21.94 mm (0.864 in) COUNTERSHAFT
Calculate the clearance by subtracting mainshaft and coun-
tershaft O.D. from gear bushing I.D..
SERVICE LIMITS:
M4: 0.10 mm (0.004 in)
C1: 0.08 mm (0.003 in)
C2: 0.08 mm (0.003 in)
C3: 0.09 mm (0.004 in)
Calculate the clearance by subtracting gear bushing O.D.
from gear |.D..
SERVICE LIMIT:
M5, M4, C1, C2, C3: 0.10 mm (0.004 in)
SHIFT FORK, SHIFT FORK SHAFT
Check for abnormal wear or deformation.
Measure the shift fork I.D. and claw thickness.
SERVICE LIMITS:
1.D.: 12.03 mm (0.474 in)
Claw thickness: 4.9 mm (0.19 in)
Check for abnormal! wear, damage or straightness.
Measure the shift fork shaft O.D..
SERVICE LIMIT: 11.95 mm (0.470 in)
11-6
SHIFT DRUM
Inspect the shift drum end for scoring, scratches, or evi-
dence of insufficient lubrication. Check the shift drum
grooves for damage.
Measure the shift drum shaft O.D. at the left side journal.
SERVICE LIMIT: 13.94 mm (0.549 in)
SHIFT DRUM JOURNAL,
SHIFT FORK SHAFT JOURNAL
Check the right and left crankcase shift fork shaft journal for
wear or damage.
Check the left crankcase shift drum journal for wear or dam-
age.
TRANSMISSION BEARING
Turn the inner race of each bearing with your finger.
The bearings should turn smoothly and quietly.
Also check that the bearing outer race fits tightly in the
crankcase.
Replace the bearings if the race does not turn smoothly and
quietly, or if they fit loosely in the crankcase (page 11-13).
ASSEMBLY
Clean all parts in solvent.
Apply molybdenum oil solution to the transmission gear shift
fork groove, transmission collar inner and outer surface and
spline collar outer surface to ensure initial lubrication.
Assemble all parts into their original positions.
CRANKCASE/TRANSMISSION/CRANKSHAFT
SHIFT DRUM
11-7
CRANKCASE/TRANSMISSION/CRANKSHAFT
MAINSHAFT
MAINSHAFT
M2 GEAR (15T)
aol
UV,
M5 GEAR (25T)
SPLINE BUSHING
SNAP RING
M3 GEAR (21T)
SPLINE WASHER
SNAP RING
M4 GEAR (23T)
M4 BUSHING
11-8
NOTE:
Check the gear freedom of movement or rotation on the
CRANKCASE/TRANSMISSION/CRANKSHAFT
C2 GEAR (29T)
C2 BUSHING WASHER
WASHER
C5 GEAR (25T)
WASHER
WASHER
C3 GEAR (30T)
SPLINE WASHER
WASHER
C4 GEAR (27T)
C1 BUSHING C1 GEAR (37T)
COUNTERSHAFT
shaft.
Install the washers and snap rings with the chamfered
edge facing the thrust load side.
Do not reuse worn snap rings which could easily spin in
the grooves.
Check that the snap rings are seated in the grooves.
Align their end gaps with the grooves of the spline. MAINSHAFT
11-9
CRANKCASE/TRANSMISSION/CRANKSHAFT
INSTALLATION MAIN/COUNTER
SHAFT ASSEMBLY
Install the mainshaft and countershaft to the left crankcase
as assembly.
NOTE:
* Do not forget to install the transmission end washer.
+ When mainshaft and countershaft installation, be careful
not to damage the countershaft oil seal.
NOTE:
Each shift fork has an identification mark; “R” is for the
right shift fork, “L” is for the left shift fork and “C” is for the
center shift fork.
SHIFT FORK MARKS
Install the shift forks to the grooves of the shifter gear with
their marks facing up (right crankcase side).
Install the shift drum aligning the guide pins on the shift
fork with the guide grooves of the shift drum.
Apply molybdenum oil solution to the shift fork shaft.
Install the shift fork shaft with its stepped end side facing
up (right crankcase side).
After installing, check for smooth transmission operation.
Assemble the crankcase (page 11-16).
11-10
CRANKSHAFT
REMOVAL
Separate the crankcase (page 11-3).
Remove the transmission (page 11-4).
Remove the crankshaft from the crankcase using a
hydraulic press.
CAUTION:
Be careful not to damage the crankcase mating surface and
crankshaft assembly.
If the crankshaft bearing is left on the crankshaft, remove
them using the bearing puller with a protector.
TOOL:
Universal bearing puller 07631 -— 0010000
NOTE:
Always replace the left bearing with a new one if it comes
out with the crankshaft.
INSPECTION
Place the crankshaft on a stand or V-blocks.
Set the indicator on the crankshaft journal.
Rotate the crankshaft two revolutions and read the runout.
SERVICE LIMIT: 0.05 mm (0.002 in)
Measure the connecting rod big end side clearance
between the connecting rod big end and the crankshaft
weight with a feeler gauge.
SERVICE LIMIT: 0.80 mm (0.031 in)
CRANKCASE/TRANSMISSION/CRANKSHAFT
CRANKSHAFT
BEARING PULLER
83 mm (3.3 in) 80 mm (3.1 in)
CRANKCASE/TRANSMISSION/CRANKSHAFT
Measure the radial clearance at the connecting rod big end,
at two points in the directions indicated by the arrows.
SERVICE LIMIT: 0.020 mm (0.0008 in)
Turn the inner race of each bearing with your finger.
The bearings should turn smoothly and quietly.
Also check the outer race of each bearing fits tightly in the
crankcase.
If you replacing the timing sprocket, align the center of the
sprocket teeth with the center of woodruff key groove as
shown.
INSTALLATION [ TCT a
Refer to the crankcase bearing installation (page 11-13).
Assemble the special tools onto the crankshaft.
Install the crankshaft drawing it.
TOOLS:
Crankcase assembly collar 07965 — VM00100
Crankcase assembly shaft 07965 — VM00200
Install the transmission (page 11-10).
Assemble the crankcase (page 11-16).
11-12
CRANKCASE BEARING REPLACEMENT
CRANKCASE BEARING/
DUST SEAL LOCATION
RIGHT SIDE;
RIGHT CRANKSHAFT
BEARING 6207
LEFT CRANKSHAFT
BEARING 28 x 72 x 18
LEFT SIDE:
CRANKSHAFT BEARING
Remove the bearings from crankcase halves.
Clean the crankcase mating surface throughly, be careful
not to damage the mating surface.
Apply engine oil to the new crankshaft bearing and place it
on the crankcase.
Set the installer (special tool) into the inner race of the bear-
ing.
Place the plate (special tool) over the installer (special tool).
NOTE:
Installer (special tool) has an identification mark.
TOOLS:
Right side:
Installer, 37.5 BRG.
Left side:
Installer, 37.42 BRG.
07XMF - KGB0200
07XMF - KGB0100
Plate, 200 x 300 x 20 07XMF - KGB0300
LEFT MAINSHAFT
BEARING 6202
wee OF
CRANKCASE/TRANSMISSION/CRANKSHAFT
RIGHT MAINSHAFT
BEARING 6204
RIGHT COUNTER-
SHAFT BEARING 6203
LEFT COUNTERSHAFT
BEARING 17 x 42 x 12
DUST SEAL
SNAP RING
INSTALLER
gS 2 BEARING
CRANKCASE
IDENTIFICATION MARK
INSTALLER
11-13
CRANKCASE/TRANSMISSION/CRANKSHAFT
Press the center of the plate (special tool) using a hydraulic
press until the plate (special tool) touch with the crankcase HYDRAULIC PRESS
surface.
CAUTION:
* Press the plate (special tool) siowly.
+ Do not damage the crankcase and bearing.
After the installation, check for the distance between the
crankshaft bearing surface (Connecting rod side) and upper
surface of the crankcase. yt”
Right side: 37.50 - 37.55 mm (1.476 - 1.478 in) BEARING
Left side: 37.42 - 37.47 mm (1.473 — 1.475 in)
TRANSMISSION BEARING
RIGHT CRANKCASE
Remove the bolts and bearing set plates from the out side
of the right crankcase.
Remove the gearshift drum bearing.
Remove the bolts and bearing set plates from the inside of
the right crankcase.
Remove the mainshaft bearing.
= MAINSHAFT
BEARING
Remove the countershaft bearing.
SHIFT DRUM BEA
: ee
Drive in new bearings into the right crankcase.
TOOLS:
Mainshaft bearing: DRIVER
Driver 07749 — 0010000 Soy
Attachment: 42 x 47 mm 07746 — 0010300
Pilot, 20 mm 07746 - 0040500
Countershaft bearing: we
Driver 07749 - 0010000 _ATTACHMENT
Attachment: 42 x 47 mm 07746 - 0010300 J Ese
Pilot, 17 mm 07746 - 0040400
Gearshift drum bearing:
Driver 07749 — 0010000
Attachment: 42 x 47 mm 07746 — 0010300
Pilot, 25 mm 07746 — 0040600
Apply locking agent to the mainshaft bearing and gearshift
drum bearing set plate bolts threads.
Install the bearing set plates and tighten the set plate bolts
to the specified torque.
TORQUE: 10 N-m (1.0 kgf-m, 7 Ibf-ft)
11-14
CRANKCASE/TRANSMISSION/CRANKSHAFT
LEFT CRANKCASE ™ ae
| SNAP RING [=
Remove the snap ring and dust seal from the outside of the
left crankcase.
Remove the countershaft bearing.
COUNTERSHAFT
BEARING
Remove the mainshaft bearing using the special tool. sige erent © Srerenreeerio™
MAINSHAFT BEARING
TOOLS: ey PRS
Bearing remover set, 15 mm 07936 —- KC10000
— bearing remover head 07936 — KC10100
— remover shaft 07936 - KC10200
— remover weight 07411 -— 0010201
Drive in new bearings to the left crankcase.
TOOLS:
Mainshaft bearing:
Driver 07749 — 0010000
Attachment: 32 x 35 mm 07746 — 0040500
Pilot, 15 mm 07746 — 0040300
Countershaft bearing:
Driver 07749 — 0010000
Attachment: 42 x 47 mm 07746 — 0010300
Pilot, 17 mm 07746 — 0040400
Apply grease to a new dust seal and drive in it to the right
crankcase (Refer to illustration/page 11-13 bearing, oil seal
location).
TOOL:
Mechanical seal driver 07PMD —- KBP0100
Install the snap ring.
DUST SEAL
11-15
CRANKCASE/TRANSMISSION/CRANKSHAFT
CRANKCASE ASSEMBLY Z
Clean and check the oil strainer screen for clog or damage. we
- Replace if necessary. a i
Apply engine oil to the rubber frame and install the strainer
screen to the right crankcase.
Clean and check the oil scavenging pipe for clog or damage SCCURScRRRE RCAF
of the rubber parts. SCAVENGING PIPE
Replace if necessary.
Apply engine oil to the rubber parts and install the scaveng-
ing pipe to the right crankcase.
Install the dowel pins.
DOWEL PINS
Apply a light but through coating of sealant to all crankcase
mating surface except the oil passage area.
11-16
CRANKCASE/TRANSMISSION/CRANKSHAFT
Install the right crankcase to the left crankcase.
RIGHT CRANKCASE ee
Install the left crankcase bolts, sealing washers and tighten
the bolts in a crisscross pattern in several steps.
BOLT/SEALING
WASHER
Apply engine oil to the front and rear cam chains and install ; 2 ee en A
to the timing sprockets. : CHAINS
Check the cam chain guide and lifter for damage and
replace if necessary. CAM CHAIN GUIDE
CAM CHAIN TENSIONER
11-17
CRANKCASE/TRANSMISSION/CRANKSHAFT
Install the front cam chain guide and collar.
Tighten the cam chain guide bolt securely.
Install the front cam chain tensioner and collar.
Apply locking agaent to the front cam chain tensioner bolt
threads and tighten it securely.
Install the rear cam chain guide and collar.
Tighten the cam chain guide bolt securely.
Install the rear cam chain tensioner and collar.
Apply locking agent to the rear cam chain tensioner bolt
threads and tighten it securely.
Install the removed parts.
11-18
BOLTS/COLLARS
BOLTS/COLLARS
“9
TENSIONER
=
MEMO
FRONT WHEEL/SUSPENSION/STEERING
24 N-m (2.4 kgf-m, 17 Ibf-ft)
ce 103 N-m (10.5 kgf-m, 76 Ibf-ft)
26 N-m (2.7 kgf-m, 20 Ibf-ft) Pe
B) mony : ok
34 N-m (3.5 kgf-m, 25 Ibf-ft)
ow |
Fy >
7, ON
4
tia '
’ ‘
tf
45
Ys
122 Nem (2.2 kgt-m, 16 IbFft
12-0
12. FRONT WHEEL/SUSPENSION/STEERING
SERVICE INFORMATION 12-1 FRONT WHEEL
TROUBLESHOOTING 12-2 FORK
HANDLEBAR 12-3. STEERING STEM
SERVICE INFORMATION
GENERAL
es i em yes tt
« A contaminated brake dise or pad reduces stopping power, Discard contaminated pads and clean contaminated disc
with a high quality brake degreasing agent.
* Wheel balance directly affects the stability, handling and overall safety of the motorcycle. Carefully check balance
before reinstalling the wheel.
* When servicing the front wheel, support the motorcycle securely with a box or other adjustable support.
* Do not operate the brake lever after removing the caliper and front wheel. To do so will cause difficulty in fitting the
brake disc between the brake pads.
¢ Refer to Section 14 for brake system information.
SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Minimum tire tread depth
Driver and passenger 200 kPa (2.0 kgf/cm?, 29 psi) | — |
Axle runout —
Wheel rim runout Radial oa
Axial =
Fork Spring free length 470.6 (18.53)
0.20 (0.008)
5 el
Tube runout
Fork fluid
117 (4.6)
346 + 2.5 cm* (11.7 + 0.08 US oz,
12.2 + 0.09 Imp oz)
Steering head bearing pre-load 0.10 — 0.15 kgf (0.220 — 0.330 Ibf)
Recommended fluid
Fluid level
Fluid capacity
12-1
FRONT WHEEL/SUSPENSION/STEERING
TORQUE VALUES
Fork bolt
Fork socket bolt
Handlebar holder bolt
Steering stem nut
Steering top thread
Top bridge pinch bolt
Bottom bridge pinch bolt
Front axle bolt
Front axle pinch bolt
Front brake disc bolt
Throttle housing screw
TOOLS
Bearing remover head, 15 mm
Attachment, 42 x 47 mm
Pilot, 15 mm
Driver
Bearing remover shaft
Fork seal driver boby
Fork seal driver attachment
Steering stem cap nut wrench
Steering stem socket wrench
Steering stem driver
— Attachment
— Driver
TROUBLESHOOTING
Hard steering
* Steering top thread too tight
* Faulty steering head bearings
* Damaged steering head bearings
Faulty tire
* Insufficient tire pressure
22 N-m (2.2 kgf-m, 16 Ibf-ft)
20 N-m (2.0 kgf-m, 14 Ibf-ft)
24 N-m (2.4 kgf-m, 17 Ibf-ft)
103 N-m (105 kgf-m, 76 Ibf-ft)
See page 13-27
26 N-m (2.7 kgf-m, 20 Ibf-ft)
34 N-m (3.5 kgf-m, 25 Ibf-ft)
66 N-m (6.7 kgf-m, 48 Ibf-ft)
22 N-m (2.2 kgf-m, 16 Ibf-ft)
42 N-m (4.3 kgf-m, 31 Ibf-ft)
4N-m (0.4 kgf-m, 2.9 Ibf-ft)
07746 — 0050400
07746 — 0010300
07746 — 0040300
07749 — 0010000
07746 — 0050100
07747 — 0010100
07947 — KA20200
07716 — 0020400
07916 — 3710101
07946 — MB00000
07953 — MJ10100
07953 — MJ10200
Soft suspension
* Weak fork spring
+ Low fluid level in fork
¢ Insufficient fluid in fork
* Lowtire pressure
Hard suspension
Steers to one side or does not track straight * High tire pressure
* Bent fork
+ Faulty steering head bearings
* Damaged steering head bearings
* Bent frame
* Worn wheel bearings
« Bent front axle
* Worn swingarm pivot component
Front wheel wobbling
* Worn wheel bearings
* Faulty tire
* Unbalanced tire and wheel
12-2
* Bent fork
* High fluid level in fork
* Incorrect fluid weight
* Clogged fluid passage
Front suspension noisy
* Loose fork fasteners
* Insufficient fluid in fork
Wheel turns hard
* Faulty wheel bearings
* Bent front axle
* Brake drug
* Faulty speed sensor gear
FRONT WHEEL/SUSPENSION/STEERING
HANDLEBAR REARVIEW MIRRORS
REMOVAL
Remove the wire bands.
Remove the rearview mirrors.
Remove the right and left screws and both handlebar
weight.
Disconnect the clutch switch wires from the switch.
Remove the clutch lever holder bolts, holder and clutch lever
bracket assembly.
CLUTCH LEVER @
BRACKET :
CLUTCH SWITCH WIRES
BOLTS ee HOLDER
Remove the left handlebar switch screws and switch. LEFT HANDLEBAR SWITCH
SCREWS
12-3
FRONT WHEEL/SUSPENSION/STEERING
Disconnect the front brake switch wires from the switch. az
Remove the master cylinder holder bolts, holder and mas- MASTER CYLINDER ASSEMBLY
ter cylinder assembly. ——
BRAKE SWITCH
~ WIRES
Remove the screws and upper housing. UPPER THROTTLE HOUSING
SCREWS
Remove the throttle cable guide.
Disconnect the throttle cables from the throttle pipe and THROTTLE CABLES
remove the throttle housing.
Remove the throttle pipe.
CABLE GUIDE
Remove the screws and right handlebar switch.
SCREWS
12-4
Remove the upper holder bolts, holders and handlebar.
INSTALLATION
Install the upper holders on the handlebar with their punch
marks forward.
Install the upper holders and temporarily tighten the upper
holder bolts.
Align the punch mark on the handlebar with the top of the
lower holders.
Tighten the front bolts first, then tighten the rear bolts to
the specified torque.
TORQUE: 24 N-m (2.4 kgf-m, 17 Ibf-ft)
Apply Honda Bond A or equivalent to the inside of the grip
and to the clean surfaces of the left handlebar and throttle
grip.
Wait 3 - 5 minutes and install the grip.
Rotate the grip for even application of the adhesive.
NOTE:
Allow the adhesive to dry for an hour before using.
Install the right handlebar switch housing onto the handle-
bar, aligning the locating pin with the hole in the handlebar.
FRONT WHEEL/SUSPENSION/STEERING
HANDLEBAR eS UPPER HOLDER = -
HONDA BOND
A or equivalent
GRIP
FRONT WHEEL/SUSPENSION/STEERING
Install the attaching screws and tighten the forward screw
first, then tighten the rear screw securely.
SCREWS
Apply grease to the throttle grip inner surface and throttle
cable contact point.
Install the throttle grip to the handlebar.
Apply grease to the throttle cable ends.
Connect the throttle cables to the throttle pipe. Saad THROTTLE CABLES
- CABLE GUIDE
Install the throttle cable guide.
Align the end of the lower housing with the punch mark on
the handlebar.
Install the throttle upper housing.
Tighten the throttle housing screws to the spcified torque.
ALIGN
TORQUE: 4 N-m (0.4 kgf-m, 2.9 Ibf-ft)
CABLE GUIDE
12-6
FRONT WHEEL/SUSPENSION/STEERING
j ; h “ ”
mi a master cylinder and holder with the “UP” mark PUN MINT VIASTER CYLINDER ASSEMBLY
Align the end of the master cylinder with the punch mark on \ y ae
the handlebar and tighten the upper bolt first, then tighten \
the lower bolt to the specified torque.
TORQUE: 12 N-m (1.2 kgf-m, 9 Ibf-ft) ;
=» BRAKE SWITCH
Connect the front brake switch wires to the switch. 5 WIRES
a
Install the left handlebar switch housing onto the handle-
bar, aligning the locating pin with the hole in the handlebar.
& SWITCH HOUSING
Install the screws and tighten the forward screw then tighten
the rear screw. LEFT HANDLEBAR SWITCH
SCREWS
Install the clutch lever bracket assembly aligning the end of
the bracket with the punch mark on the handlebar.
Install the clutch lever bracket holder with the “UP” mark
facing up.
Tighten the upper bolt first, then the lower bolt.
CLUTCH LEVER
BRACKET
CLUTCH SWITCH WIRES
Connect the clutch switch wires.
FRONT WHEEL/SUSPENSION/STEERING
Install the handlebar weight on to the inner weight, aligning
the bosses and grooves each other.
WEIGHT
Install the each side screws and tighten it while holding the
weight.
Install the wire bands. REARVIEW MIRRORS
Install the rearview mirrors.
12-8
FRONT WHEEL/SUSPENSION/STEERING
FRONT WHEEL
REMOVAL
Support the motorcycle securely using a hoist or equiva-
lent.
Loosen the front axle pinch bolt.
Remove the axle and the front wheel.
Remove the speed sensor gear box from the left wheel hub.
NOTE:
Do not damage the speed sensor wire.
PINCH BOLT
SPEED SENSOR GEAR BOX
Remove the side collar from the right wheel hub.
Remove the dust seal from the right wheel hub.
INSPECTION
Set the axle in V-blocks and measure the runout.
Actual runout is 1/2 the total indicator reading.
SERVICE LIMIT: 0.20 mm (0.008 in)
FRONT AXLE
12-9
FRONT WHEEL/SUSPENSION/STEERING
Turn the inner race of each bearing with your finger.
The bearings should turn smoothly and quietly.
Also check that the bearing outer race fits tightly in the hub.
Remove and discard the bearings if they do not turn
smoothly, quietly, or if they fit loosely in the hub.
NOTE:
Replace the bearings in pairs.
Pack new bearings with grease and install them into the
hub using the special tools (page 12-12).
Check the rim runout by placing the wheel in a turning
stand.
Spin the wheel by hand, and read the runout using a dial
indicator.
Actual runout is 1/2 the total indicator reading.
SERVICE LIMIT:
Radial: 1.0 mm (0.04 in)
Axial: 1.0 mm (0.04 in)
Wheel balance
CAUTION:
Wheel balance directly affects the stability, handling and
over all safety of the motorcycle.
Always check balance when the tire has been removed
from the rim.
NOTE:
For optimum balance, the tire balance mark (a paint dot on
the side wall) must be located next to the valve stem.
Remount the tire if necessary.
To balance the wheel, install balance weights on the light-
est side of rim, the side opposite the chalk mark.
Add just enough weight so the wheel will no longer stop in
the same position when it is spun.
Do not add more than 60 g (2.1 0z) to the wheel.
Note the rotating direction mark on the tire.
12-10
(1) WHEEL BEARING
BALANCE MARK
Yew
ROTATING DIRECTION MARK
VaoWN
FRONT WHEEL/SUSPENSION/STEERING
Remove the dust seals from the wheel.
Mount the wheel, tire and brake discs assembly in an
inspection stand.
Spin the wheel, allow it to stop, and mark the lowest (heavi-
est) point of the wheel with a chalk.
Do this two or three times to verify the heaviest area.
If the wheel is balanced, it will not stop consistently in the
same position.
To balance the wheel, install wheel weights on the highest
side of the rim, the side opposite the chalk marks. Add just
enough weight so the wheel will no longer stop in the same
position when it is spun.
Do not add more than 60 grams to the wheel.
DISASSEMBLY " DUST SEAL
Remove the dust seal.
Remove the mounting bolts and brake disc.
NOTE:
Check for disc warpage; see page 14-8.
WHEEL BEARING REPLACEMENT
Install the bearing remover head into the bearing.
From the opposite side install the bearing remover shaft
and drive the bearing out of the wheel hub.
Remove the distance collar and drive out the other bearing.
TOOLS:
Bearing remover head,15mm 07746 - 0050400
Bearing remover shaft 07746 — 0050100
REMOVER HEAD REMOVER SHAFT
12-11
FRONT WHEEL/SUSPENSION/STEERING
ASSEMBLY
42 N-m (4.3 kgf-m, 31 Ibf-ft)
BEARING
DISTANCE COLLAR
RETAINER
BRAKE DISC
oy
=e
Tamas
DUST SEAL
“GG
D _ cas
DUST SEAL
BEARING
Pack all bearing cavities with grease.
DRIVER
Drive in a new left bearing squarely with its sealed side fac-
ing out.
Install the distance collar, then drive in the right side bear-
ing with its sealed side facing out.
TOOLS:
Driver 07749 - 0010000
Attachment, 42 x 47 mm 07746 — 0010300
Pilot, 15 mm 07746 -— 0040300
SS «se
Do not get grease on the brake discs or stopping power
will be reduced.
Install the brake disc with the stamped mark “MIN. TH
3.5MM"” facing outside and install the brake disc bolts.
Tighten the brake disc bolts to the specified torque.
TORQUE: 42 N-m (4.3 kgf-m, 31 Ibf-ft)
12-12
FRONT WHEEL/SUSPENSION/STEERING
Apply grease to the new dust seal lips then install it into the so
Rg tas DUST SEAL
wheel hub.
Apply grease to the speed sensor gear retainer, and install
it into the left side hub aligning its tabs with the slots in the
hub.
Apply grease to the new dust seal lips, them install them
into the wheel hub.
Install the right side collar.
FRONT WHEEL/SUSPENSION/STEERING
INSTALLATION
FRONT AXLE
Install the speed sensor gear box into the left wheel hub.
Install the wheel assembly onto the fork legs so that the
brake disc is positioned between the pads, being careful not
to damage the pads. Position the lug on the gear box
against the back of the stopper on the fork leg.
Make sure the speed sensor gear box and left fork leg
aligning as shown.
Tighten the front axle to the specified torque.
TORQUE: 66 N-m (6.7 kgf-m, 48 Ibf-ft)
SPEED SENSOR
GEAR BOX
FORK
REMOVAL
Remove the following:
— Front wheel (page 12-9)
— Front brake caliper (page 14-17)
— Front fender (page 2-3)
Loosen the left and right fork bolts but do not remove yet.
Loosen the left and right top bridge pinch bolts.
Loosen the fork bottom bridge pinch bolts while holding
the fork.
Remove the fork from the steering stem.
12-14
DISASSEMBLY
Remove the fork bolt and O-ring from the fork tube.
4.
The fork bolt is under spring pressure. Use care when
removing it and wear eye and face protection.
Remove the spring collar, spring seat.
Remove the fork spring.
Pour out the fork fluid by pumping the fork tube several
times.
CAUTION:
Do not over tighten the fork slider.
Hold the fork slider in a vise with a piece of wood or soft
jaws to avoid damage.
Loosen and remove the fork socket bolt and sealing washer
from the fork slider.
If the fork piston turns with the socket bolt, temporarily
install the fork spring, washer, spring seat and fork bolt.
FRONT WHEEL/SUSPENSION/STEERING
FORK BOLT
SPRING COLLAR
SPRING SEAT
FORK SPRING
_ SOCK
Dower yee:
FRONT WHEEL/SUSPENSION/STEERING
Remove the oil lock piece from the fork slider.
OIL LOCK PIECE
FORK TUBE FORK SLIDER ~~
Remove the fork piston and rebound spring from the fork URE RN maT
tube. REBOUND SPRING ~
NOTE: a
Do not remove the fork piston ring, unless it is necessary to
replace with a new one.
Remove the dust seal from the fork slider.
DUST SEAL
FORK SLIDER
Remove the stopper ring from the groove of the fork slider.
CAUTION:
Do not scratch the fork tube sliding surface.
STOPPER RING
12-16
FRONT WHEEL/SUSPENSION/STEERING
NOTE:
Check that the fork tube moves smoothly in the fork slider.
If does not, check the fork tube for bending or damage, and
bushings for wear or damage.
Using quick successive motions, pull the fork tube out of
the fork slider.
Remove the oil seal, back-up ring and slider bushing from
the fork tube. - FORK TUBE
OIL SEAL _ SLIDER BUSH
= BUSHING
NOTE:
Do not remove the fork tube bushing unless it is necessary
to replace it with a new one.
Carefully remove the fork tube bushing by plying the slot
with a screwdriver until the bushing can be pulled off by
hand.
BACK-UP RING ©
INSPECTION
FORK SPRING
Measure the fork spring free length by placing the spring
on a flat surface.
SERVICE LIMIT: 461 mm (18.15 in)
FORK TUBE/SLIDER/FORK PISTON
Check the fork tube, slider and fork piston for score marks, FORK SLIDER
and excessive or abnormal wear. ge
Check the fork piston ring for wear or damage.
Check the rebound spring for fatigue or damage.
Replace the component if necessary.
FORK PISTON TUBE
12-17
FRONT WHEEL/SUSPENSION/STEERING
Set the fork tube in V-blocks and measure the fork tube
runout rotating it with a dial indicator.
Actual runout is 1/2 the total indicator reading.
SERVICE LIMIT: 0.20 mm (0.008 in)
Replace if the service limit is exceeded, or there are scratches
or nicks that will allow fork oil to leak past the seals.
NOTE:
nie SE ee ee re
Do not reuse the fork tube if it cannot be perfectly straight-
ened with minimal effort.
FORK TUBE BUSHING
Visually inspect the slider and fork tube bushings. BACK-UP RING
Replace the bushings if there is excessive scoring or
scratching, or if the teflon is worn so that the copper sur-
face appears on more 3/4 of the entire surface.
Check the back-up ring; replace it if there is any distortion at :
the point shown. é
COPPER SURFACES CHECK POINTS
SPACER
FORK CAP
SPRING SEAT
PISTON RING
D oust sear K
STOPPER RING
SP onsear ae /
BACK-UP RING S
SLIDER /
BUSHING iS
ep FORK TUBE Lifes
™s BUSHING
FORK
PISTON
OIL LOCK D>
PIECE i
we
SEARING REBOUND
WASHER SPRING
3 FORK SPRING
Me FORK TUBE
FORK SOCKET BOLT
12-18
FRONT WHEEL/SUSPENSION/STEERING
Install a new fork tube bushing if the tube bushing has been
removed. c eg Pon | OIL SEAL ;
CAUTION: en
« Be careful not to damage the fork tube bushing coating.
¢ Do not open the fork tube bushing more than necessary.
SLIDER BUSHING
NOTE:
Remove the burrs from the bushing mating surface, being
careful not to peel off the coating. =
Install the slider bushing and back-up ring to the fork tube. BACK-UP RING Rg FORK TUBE BUSHING
Apply fork oil to the new oil seal lip. ——* -
Install the new oil seal to the fork tube with it marking side
facing up.
REBOUND SPRING
Install the rebound spring to the fork piston.
Install the fork piston into the fork tube.
FORK TUBE
Install the oil lock piece onto the fork piston end.
Coat the fork tube bushing with the fork oil and install the P Fork | FORK TUBE OIL LOCK PIECE
fork into the fork slider. BUSHING
FORK SLIDER
CAUTION:
Do not overtighten fork slider.
oy SEALING
me WASHER
Hold the axle holder of the fork slider in a vise with a piece
of wood or soft jaws to avoid damage.
Replace the sealing washer with a new one.
Clean and apply a locking agent to the fork socket bolt
threads and install the fork socket bolt with the new sealing
washer into the fork piston.
SOCKET _
BOLT
12-19
FRONT WHEEL/SUSPENSION/STEERING
Tighten the fork socket bolt to the specified torque.
TORQUE: 20 N-m (2.0 kgf-m, 14 Ibf-ft)
If the fork piston turns with the socket bolt, temporarily
install the fork spring, spring seat, spring collar and fork
cap.
Drive in the new oil seal into the fork tube until the stop
ring groove is visible, using the special tool. DRIVER BODY
TOOLS:
Fork seal driver body 07747 - 0010100
Attachment 07947 - KA20200
og “ee
Install the stopper ring into the groove in the fork slider.
STOPPER RING
Apply fork oil to the lip a new dust seal and install the dust
seal. ong FORK |
DUST SEAL
12-20
FRONT WHEEL/SUSPENSION/STEERING
Pour the specified amount of recommended fork fluid into
the fork tube.
FORK FLUID CAPACITY:
346 + 2.5 cm® (11.7 + 0.08 US oz, 12.2 + 0.09 Imp oz)
Pump the fork tube several times to remove trapped air
from the lower portion of the fork tube.
Compress the fork leg fully and measure the oil level from
the top of the fork tube.
FORK OIL LEVEL: 117 mm (4.6 in)
Wipe oil off the spring thoroughly using a clean cloth.
Install the fork spring with the tapered end facing down.
Install the spring seat and spring collar.
SPRING COLLAR
SPRING SEAT
12-21
FRONT WHEEL/SUSPENSION/STEERING
Coat a new O-ring with fork fluid and install it onto the fork FORK BOLT
bolt.
Install the fork bolt loosely.
NOTE:
Install the fork bolt but do not tighten yet.
INSTALLATION
Install the fork tube into the steering stem and fork top
bridge.
Align the top end of the fork tube with the upper surface of
the top bridge as shown.
Tighten the bottom bridge pinch bolts.
TORQUE: 34 N-m (3.5 kgf-m, 25 Ibf-ft)
Tighten the left and right top bridge pinch bolts to the speci-
fied torque.
FORK BOLT
Os
TORQUE: 26 N-m (2.7 kgf-m, 20 Ibf-ft)
Tighten the fork bolts to the specified torque if it was
removed.
TORQUE: 22 N-m (2.2 kgf-m, 16 Ibf-ft)
Install the following:
— Front fender (page 2-3)
— Front brake caliper (page 14-20)
— Front wheel (page 12-14) PINCH BOLT
12-22
FRONT WHEEL/SUSPENSION/STEERING
STEERING STEM
REMOVAL
— Front forks (page 12-14)
— Handlebar (page 12-3)
— Inner center cowl (page 2-6)
— Front cowl assembly (page 2-7)
Remove the brake hose clamp bolt and brake hose from the
steering stem.
Remove the mount bolts and front cowl bracket.
Remove the stem nut and washer using the special tool.
cS pes
ii -
@ STEM NUT/WASHER
TOOLS:
Steering stem cap nut wrench 07716 - 0020400
STEERING STEM
CAP NUT WRENCH
Remove the top bridge.
TOP BRIDGE
12-23
FRONT WHEEL/SUSPENSION/STEERING
Remove the steering top thread using special tool.
STEERING STEM
TOOL: SOCKET WRENCH
Steering stem socket 07916 - 3710101
TOP THREAD ~
Hold the steering stem and remove the steering top thread,
upper bearing inner race and upper bearing. TOP THREAD
ahs
-
RACE ©
Remove the steering stem from the steering head.
Check the lower bearing, inner and outer races for wear or
damage.
STEERING BEARING RACE REPLACEMENT
NOTE:
Always replace the bearings and races as a set.
DRIVER
Remove the lower bearing outer race using the following
tools.
TOOLS:
Driver 07953 —- MJ10200
Attachment 07953 - MJ10100
OUTER RACE 5
ATTACHMENT
12-24
Remove the upper bearing outer race using the following
tools.
TOOLS:
Driver 07953 — MJ10200
Attachment 07953 —- MJ10100
Install the steering stem nut onto the stem to prevent the
threads from being damaged when removing the lower
bearing inner race from the stem.
Remove the lower bearing inner race with a chisel or equiva-
lent tool, being careful not to damage the stem.
Remove the dust seal and washer.
Install the washer onto the steering stem.
Apply grease to new dust seal lips and install it over the
steering stem.
Install a new lower bearing inner race using a special tool
and a hydraulic press.
TOOL:
Steering stem driver 07946 —- MB00000
Drive the new upper bearing outer race into the head pipe
using the following tools.
TOOLS:
Driver 07749 - 0010000
Attachment, 42 x 47 mm 07746 - 0010300
FRONT WHEEL/SUSPENSION/STEERING
OUTER RACE ...
LOWER INNER RACE
ibppeetr ooh ad ATTACHMENT
STEM NUT
DUST SEAL/WASHER
STEERING STEM
DRIVER
LOWER INNER RACE
ATTACHMENT
S OUTER RACE fy
12-25
FRONT WHEEL/SUSPENSION/STEERING
Drive the new lower bearing outer race into the head pipe
using the following tools. ATTACHMENT
ACE
TOOLS: = SS
Driver 07749 - 0010000 gs i BA
Attachment, 42 x 47 mm 07746 — 0010300
ASSEMBLY
STEERING TOP
THREAD
ov UPPER BEARING
ee INNER RACE
UPPER BEARING
Pew UPPER BEARING
"es OUTER RACE
Pew LOWER BEARING
es = =OUTER RACE
LOWER
SS cam
BEARING
q@ip LOWER BEARING
INNER RACE
DUST SEAL
STEERING STEM
Apply grease to the new lower bearing.
Install the new lower bearing onto the steering stem.
Install the steering stem into the head pipe.
SS —SGESH LOWER BEARING
12-26
FRONT WHEEL/SUSPENSION/STEERING
Apply grease to the new upper bearing.
Apply oil to the steering top thead bolt.
Install the upper bearing, upper bearing inner race, and
steering top thread.
ae , Bor THREAD
INNER RACE ©
Tighten the top thread to the specified torque.
STEERING STEM SOCKET
TOOL:
Steering stem socket 07916 - 3710101
TORQUE: 34 N-m (3.5 kgf-m, 25 Ibf-ft)
TOP THREAD
Turn the steering stem right and left, lock-to-lock at least
five times to seat bearings.
Make sure that the steering stem moves smoothly, without
play or binding.
Loosen the top thread completely.
Retighten the top thread to the specified torque.
STEERING STEM SOCKET
TOOL:
Steering stem socket 07916 — 3710101
TORQUE: 15 N-m (1.5 kgf-m, 11 Ibf-ft)
Rotate the top thread counterclockwise 45 degrees.
TOP THREAD
12-27
FRONT WHEEL/SUSPENSION/STEERING
Install the top bridge.
Install the washer and stem nut.
Temporarily install the front forks.
Tighten the steering stem nut to the specified torque.
TORQUE: 103 N-m (10.5 kgf-m, 76 Ibf-ft)
TOOL:
Steering stem cap nut wrench 07716 - 0020400
INSTALLATION
Install the front cowl bracket.
Install and tighten the front cowl mount bolts.
Install the brake hose clamp and brake hose.
Install and tighten the bolt.
Install the following:
— Front cowl assembly (page 2-7)
— Inner center cowl (page 2-6)
— Handlebar (page 12-5)
— Front forks (page 12-22)
STEM NUT :
STEERING STEM
CAP NUT WRENCH
12-28
STEERING BEARING PRELOAD
Raise the front wheel off the ground.
Position the steering stem to the straight ahead position.
Hook a spring scale to the fork tube between the fork top
and bottom bridges.
Make sure that there is no cable or wire harness interfer-
ence.
Pull the spring scale keeping the scale at a right angle to the
steering stem.
Read the scale at the point where the steering stem just
starts to move.
STEERING BEARING PRELOAD:
0.10 — 0.15 kgf (0.220 - 0.330 Ibf)
If the readings do not fall within the limits, readjust the
steering top thread.
Install the removed parts in the reverse order of removal.
FRONT WHEEL/SUSPENSION/STEERING
12-29
REAR WHEEL/SUSPENSION
88 N-m (9.0 kgf-m, 65 Ibf-ft)
44 N-m (4.5 kgf-m, 33 Ibf-ft)
44 N-m (4.5 kgf-m, 33 Ibf-ft)
88 N-m (9.0 kgf-m, 65 Ibf-ft)
13-0
13. REAR WHEEL/SUSPENSION
SERVICE INFORMATION 13-1 SHOCK ABSORBER
TROUBLESHOOTING 13-2 SWINGARM
REAR WHEEL 13-3
SERVICE INFORMATION
GENERAL
+ A contaminated brake disc or pad reduces stopping power, Discard contaminated pads and clean contaminated disc
with a high quality brake degreasing agent.
+ Wheel balance directly affects the stability, handling and overall safety of the motorcycle. Carefully check balance
before reinstalling the wheel.
CAUTION:
To avoid damaging the rim when using the tire lever, always use rim protectors.
* When servicing the rear wheel, swingarm or shock absorber, support the motorcycle securely with a using a hoist or
equivalent.
* Use only genuine Honda replacement bolts and nuts for all suspension pivot and mounting points.
SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD
Minimum tire tread depth —_-
Driver only 200 kPa (2.0 kgf/cm’, 29 psi) —
Driver and passenger 225 kPa (2.25 kgf/cm’, 33 psi) —
Axle runout 0.20 (0.008)
Radial — 1.0 (0.04)
— 1.0 (0.04)
60 g (2.1 0z) max.
Wheel rim runout
Wheel balance weight
25 — 35 (1-1 3/8)
110
aK 520 SMOZ ae
Drive chain slack
Drive chain link
Drive chain size
TORQUE VALUES
Rear axle nut 88 N-m (9.0 kgf-m, 65 Ibf-ft)
Driven sprocket nut 64 N-m (6.5 kgf-m, 47 Ibf-ft)
Rear brake disc bolt 42 N-m (4.3 kgf-m, 31 Ibf-ft)
Shock absorber lower mounting nut 44 N-m (4.5 kgf-m, 33 Ibf-ft)
Shock absorber upper mounting nut 44 N-m (4.5 kgf-m, 33 Ibf-ft)
Swingarm pivot nut 88 N-m (9.0 kgf-m, 65 Ibf-ft)
Chain slider screw 3 N-m (0.3 kgf:m, 2.2 Ibf-ft)
Chain adjuster lock nut 10 N-m (1.0 kgf-m, 7 Ibf-ft)
13-1
REAR WHEEL/SUSPENSION
TOOLS
Bearing remover head, 15 mm
Bearing remover shaft
Driver
Attachment, 22 x 24 mm
Attachment, 42 x 47 mm
Attachment, 24 x 26 mm
Pilot, 15 mm
Pilot, 20 mm
Pilot, 17 mm
Bearing remover shaft, 20 mm
Bearing remover handle
Bearing remover weight
TROUBLESHOOTING
Wobble or vibration in motorcycle
* Bent wheel
* Damaged tire
« Axle not tightened properly
¢ Chain adjusters not adjusted equally
Soft suspension
*« Weak spring
* Oil leakage from damper unit
« Improper shock absorber spring preload
* Tire pressure too low
Hard suspension
* Improper shock absorber spring preload
« Bent damper rod
* Bent frame or swingarm
* Tire pressure too high
Suspension noise
* Faulty damper
* Loose fasteners
07746 — 0050400
07746 — 0050100
07749 — 0010000
07746 — 0010800
07746 — 0010300
07746 — 0010700
07746 — 0040300
07746 — 0040500
07746 — 0040400
07936 — 3710600
07936 — 3710100
07741 — 0010201
Steers to one side or does not treck straight
* Rent rear axle
* Axle alignment/chain adjustment not equal both sides
13-2
REAR WHEEL/SUSPENSION
REAR WHEEL | PME DRIVE CHAIN CASE
REMOVAL
Support the motorcycle securely using a hoist or equiva-
lent.
Remove the bolts and drive chain case from the swingarm.
Remove the rear axle nut and washers.
Loosen the drive chain adjusting nut and lock nut.
Push the rear wheel forward.
Derail the drive chain.
Remove the axle from the left side and remove the rear
wheel.
Remove the drive chain adjusters.
INSPECTION
AXLE
Place the axle in V-blocks and measure the runout.
Actual runout is 1/2 the total indicator reading.
SERVICE LIMIT: 0.20 mm (0.008 in)
WHEEL
Check the rim runout by placing the wheel in a turning
stand.
Spin the wheel slowly and read the runout using a dial indi-
cator.
Actual runout is 1/2 the total indicator reading.
SERVICE LIMITS: Radial: 1.0 mm (0.04 in)
Axial: 1.0 mm (0.04 in)
13-3
REAR WHEEL/SUSPENSION
Wheel balance
CAUTION:
Wheel balance directly affects the stability, handling and
over all safety of the motorcycle.
Always check balance when the tire has been removed
from the rim.
NOTE:
For optimum balance, the tire balance mark (a paint dot on
the side wall) must be located next to the valve stem.
Remount the tire if necessary.
BALANCE MARK
To balance the wheel, install balance weights on the light-
est side of rim, the side opposite the chalk mark.
Add just enough weight so the wheel will no longer stop in
the same position when it is spun.
Do not add more than 60 g (2.1 oz) to the wheel.
ROTATING DIRECTION MARK
Note the rotating direction mark on the tire.
WHEEL BEARING
Turn the inner race of each bearing with your finger.
Bearings should turn smoothly and quietly. Also check that
the bearing outer race fits tightly in the hub.
Remove and discard the bearings if the races do not turn
smoothly and quietly, or if they fit loosely in the hub.
NOTE:
Replace the wheel bearings in pairs.
WHEEL BEARING
DRIVEN SPROCKET
Check the condition of the final driven sprocket teeth.
Replace the sprocket if worn or damaged. NO GOOD
NOTE:
* If the final driven sprocket requires replacement, inspect
the drive chain and drive sprocket.
* Never install a new drive chain on a worn sprocket or a
worn chain on new sprockets. Both chain and sprocket
must be in good condition or the replacement chain or
sprocket will wear rapidly.
13-4
REAR WHEEL/SUSPENSION
DISASSEMBLY BcoLAR BOLTS <
Remove the collar. ae © = |. *
Remove the dust seal.
Remove the bolts and brake disc.
DUST SEAL
Remove the collar and dust seal.
Loosen the driven sprocket nuts.
P DUST SEAL = eu ;
a
Remove the driven frange from the left wheel hub, then
remove the driven sprocket nuts and sprocket.
Remove the damper rubbers and O-ring. DAMPER RUBBERS
13-5
REAR WHEEL/SUSPENSION
WHEEL BEARING REMOVAL
Install the bearing remover head into the bearing. BEARING REMOVER HEAD s
From the opposite side install the bearing remover shaft \ é ’ Ss
and drive the bearing out of the wheel hub.
Remove the distance collar and drive out the other bearing.
TOOLS:
Bearing remover head, 15mm 07746 - 0050400
Bearing remover shaft 07746 — 0050100
i
HAFT
DRIVEN FLANGE BEARING REMOVAL
Remove the driven flange bearing and collar. BEARING
ASSEMBLY
42 N-m (4.3 kgf-m, 31 Ibf-ft)
BEARING
DISC
DUST SEAL
DRIVEN FLANGE
BEARING
DRIVEN SPROCKET
DUST SEAL
64 N.m (6.5 kgf-m, 47 Ibf-ft)
REAR WHEEL/SUSPENSION
WHEEL BEARING INSTALLATION
Pack all bearing cavities with grease. ATTACHMENT DRIVER
CAUTION:
Never install an old bearing has been removed, the bearing
must be replaced with a new one.
Drive a new left bearing squarely with its sealed side facing
out.
TOOLS:
Driver 07749 - 0010000
Attachment, 42 x 47 mm 07746 — 0010300
Pilot, 15 mm 07746 -— 0040300
Install the distance collar, then drive in the right side bear-
ing with its sealed side facing out. DRIVER
DRIVEN FLANGE BEARING INSTALLATION
Install the driven flange collar to the new drive flange bear-
ing using the special tools.
oy
TOOLS: bod
Driver 07749 -— 0010000 BEARING
Pilot, 15 mm 07746 -— 0040300
COLLAR PILOT
Drive the driven flange bearing and collar into the driven | | ;
flange using the special tools. ATTACHMENT DRIVER
TOOLS:
Driver 07749 - 0010000
Attachment, 42 x 47 mm 07746 — 0010300
Pilot, 15 mm 07746 - 0040300
BEARING/COLLAR ‘PILOT
Install the damper rubbers into the wheel hub.
Apply grease to a new O-ring and install it to the wheel DAMPER RUBBERS
hub. 2 3
13-7
REAR WHEEL/SUSPENSION
I
Install the driven flange assembly into the left wheel hub. za
Install the driven sprocket and tighten the nuts to the speci- DRIVEN FLANGE ASSEMBLY
fied torque. PP ot
TORQUE: 64 N-m (6.5 kgf-m, 47 Ibf-ft)
Apply grease to the new dust seal lips, then install the dri-
ven flange.
eg —SGEEH DUST SEAL
RS SRS ETS:
Install the collar into the driven flange.
Install the rear brake disc with the stamped mark “MIN. TH oa
3.5MM” facing outside and install the brake disc bolts. BRAKE DISC §&
Tighten the brake disc bolts to the specified torque.
TORQUE: 42 N-m (4.3 kgf-m, 31 Ibf-ft)
13-8
REAR WHEEL/SUSPENSION
Apply grease to the new dust seal lips, then install it in to
the wheel hub.
e
T SEAL *
l 0 *
NSTALLATION ADJUSTING NUT WASHER
Check the rear brake cariper bracket position (page 14-24). a ee z és )
Install both drive chain adjusters into the swingarm. a / rer
Place the rear wheel into the swingarm carefully aligning LOCK NUT
the brake disc between the brake pads.
Insert the axle through the left drive chain adjuster, left side
collar, wheel, right side collar, rear caliper bracket and right
chain adjuster.
Install the drive chain onto the driven sprocket.
Install the washer and loosely install the axle nut. DRIVE CHAIN ADJUSTER 2 AXLE NUT
Adjust the drive chain slack (page 3-16). Ee
Tighten the axle nut to the specified torque.
TORQUE: 88 N-m (9.0 kgf-m, 65 Ibf-ft)
Install and slide the drive chain case by aligning the groove
with the boss of the swingarm and chain case.
Tighten the bolts securely.
13-9
REAR WHEEL/SUSPENSION
SHOCK ABSORBER —
REMOVAL
Support the motorcycle securely using a hoist or equiva-
lent.
Remove the following:
— Seat (page 2-2).
— Side cover (page 2-2).
— Rear wheel (page 13-3).
Remove the shock absorber lower mount bolt and nut.
Remove the shock absorber upper mount bolt and nut.
UPPER MOUNT BOLT/NUT
INSPECTION
DAMPER
Visually inspect the shock absorber for damage.
Check the following:
— Damper rod for bend or damage
— Damper unit for deformation or oil leaks
— Upper mounting bushing for wear or damage
CAUTION:
« Do not disassemble the shock absorber.
¢ Replace the shock absorber if any component is dam-
aged.
BUSHING
NEEDLE BEARING REPLACEMENT
Remove the collar from the shock absorber.
Remove the dust seals and needle bearing.
COLLAR NEEDLE BEARING
13-10
REAR WHEEL/SUSPENSION
Pack the new needle bearings with multi purpose grease.
Press the needle bearings into the shock arm until the bear- 7.88.2 mae
ing outer ends are on a level with the shock arm inner DRIVER (0.31 — 0.32 in)
edges,
NOTE:
Press the needle bearing on the stamped end.
TOOLS:
Driver 07749 -— 0010000
Attachment, 24 x 26 mm 07746 — 0010700
Pilot, 17 mm 07746 - 0040400 Koa
BEARING PILOT BEARING
Install the dust seals into the shock absorber.
Install the collar.
NEEDLE BEARING
INSTALLATION UPPER MOUNT BOLT/NUT
Install the shock absorber to the frame.
Install and tighten the shock absorber upper mount bolt to
the specified torque.
TORQUE: 44 N-m (4.5 kgf-m, 33 Ibf-ft)
Install and tighten the shock absorber lower mount nut to
the specified torque.
TORQUE: 44 N-m (4.5 kgf-m, 33 Ibf-ft)
Install the following:
— Rear wheel (page 13-9).
— Side cover (page 2-2).
— Seat (page 2-2).
Check the operation of the shock absorber (page 3-24).
13-11
REAR WHEEL/SUSPENSION
SHOCK ABSORBER DISPOSAL
Center punch the damper case to mark the drilling point.
(Refer to right illustration).
Wrap the shock absorber inside a plastic bag.
Support the shock absorber upright in a vise as shown.
Through the open end of the bag, insert a drill motor with a
sharp 2-3 mm (5/64 — 1/8 in) drill bit.
* Do not use a dull drill bit which could cause a build-up of
excessive heat and pressure inside the damper, leading to
explosion and severe personal injury.
* The shock absorber contains nitrogen gas and oil under
high pressure. Do not drill any further down the damper
case than the measurement given above, or you may drill
into the oil chamber; oil escaping under high pressure
may cause serious personal injury.
* Always wear eye protection to avoid getting metal shav-
ings in your eyes when the gas pressure is released. The
plastic bag is only intended to shield you from the escap-
ing gas.
Hold the bag around the drill motor and briefly run the drill
motor inside the bag; this will inflate the bag with air from
the motor and help keep the bag from the getting caught in
the bit when you start.
SWINGARM * LOWER MOUNT
BOLT/NUT
REMOVAL hoe "
BRAKE HOSE
CLAMP
2
Remove the rear wheel (page 13-3).
Remove the bolt from the brake hose clamp.
Remove the brake caliper assembly from the swingarm.
Remove the shock absorber lower mount bolt and nut
(page 13-10).
Remove the swingarm pivot nut.
Remove the pivot bolt from the left side and remove the
swingarm.
. 4
PIVOT COVER
| PIVOT BOLT/NUT
13-12
REAR WHEEL/SUSPENSION
a
DISASSEMBLY
Check the drive chain slider for wear or damage.
Remove the drive chain adjusters.
INA
Remove the screws and drive chain slider. aay
Remove the swingarm dust seal caps. BDUST SEAL CAPS
re
cco om
SHEEP, ae
N SLIDER
Remove the pivot shaft.
Remove the needle bearing from the swingarm using the
special tool.
TOOLS:
Bearing remover shaft,20mm _ 07936 - 3710600
Bearing remover handle 07936 - 3710100
Bearing remover weight 07741 - 0010201
WEIGHT
REAR WHEEL/SUSPENSION
Check the following:
Pivot seal cap damage — Replace
Pivot shaft damage — Replace
Needle bearing damage — Replace
Swingarm damage — Replace
PIVOT SEAL CAP
Apply grease to the new needle bearing. DRIVER
Press a needle bearing into the swingarm using the special
tools. '
TOOLS: ATTACH-
Driver 07749 - 0010000 becker
Attachment, 24 x 26 mm 07746 — 0010700
Pilot, 20 mm 07746 - 0040300
=
BEARING
ASSEMBLY
Q
Zi, a=
Cy
Q
a>
Reng NEEDLE BEARING Eo
: CHAIN ADJUSTER
SWINGARM
CHAIN SLIDER
PIVOT SEAL CAP ,
=. —— WASHER
“@ mi 3 N-m (0.3 kgf-m, 2.2 Ibf-ft)
PIVOT SHAFT
13-14
REAR WHEEL/SUSPENSION
Apply grease to the pivot shaft and install it into the
swingarm.
Apply grease to the dust seal cap inside and install them to
the swingarm.
Install the drive chain slider onto the swingarm aligning its
bosses with the holes in the swingarm.
Install and tighten the screws to the specified torque.
TORQUE: 3 N-m (0.3 kgf-m, 2.2 Ibf-ft)
REAR WHEEL/SUSPENSION
Install the drive chain adjusters.
INSTALLATION
Install the swingarm onto the frame.
Install the swingarm pivot bolt to the frame from the left
side.
Install and tighten the swingarm pivot nut to the specified
torque.
TORQUE: 88 N-m (9.0 kgf-m, 6.5 Ibf-ft)
Install the pivot cover.
Install the shock absorber lower mount bolt/nut (page 13-
11).
Install the brake caliper assembly by aligning the boss of
the swingarm and hole of the caliper bracket.
Install the brake hose clamp and tighten the bolt securely.
Install the rear wheel (page 14-9).
~ BRAKE HOSE
CLAMP
13-16
MEMO
BRAKE SYSTEM
2 N-m (0.2 kgf-m, 1.4 Ibf-ft)
30 N-m (3.1 kgf-m,
22 Ibf-ft)
12 N-m (1.2 kgf-m, 9 Ibf-ft)
34 N-m (3.5 kgf-m, 25 Ibf-ft)
12 N-m (1.2 kgf-m, 9 Ibf-ft)
12 N-m (1.2 kgf-m, 9 Ibf-ft)
G
‘ a
pat ff
Or,
df
34 N-m (3.5 kgf-m, 25 Ibf-ft)
ge
Y
Ce,
Ce
a,
%
SS
14-0
14. BRAKE SYSTEM
SERVICE INFORMATION - FRONT MASTER CYLINDER
TROUBLESHOOTING - REAR MASTER CYLINDER
BRAKE FLUID REPLACEMENT/ FRONT BRAKE CALIPER
AIR BLEEDING REAR BRAKE CALIPER
BRAKE PAD/DISC -5 BRAKE PEDAL
SERVICE INFORMATION
GENERAL
rn ee
A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc
with a high quality brake degreasing agent.
Keep grease off of brake pads and disc.
Never allow contaminates (dirt, water, etc.) to get into an open reservoir.
Once the hydraulic system has been opened, or if the brake feels spongy, the system must be bled.
Always use fresh DOT 3 or DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different
types of fluid they may not be compatible.
CAUTION:
Spilled brake fluid will severely damage instrument lenses and painted surfaces. It is also harmful to some rubber
parts.
Be careful whenever you remove the reservoir cap; make sure the front reservoir is horizontal first.
+ Always check brake operation before riding the motorcycle.
SPECIFICATIONS
Unit: mm (in)
Specified brake fluid
Brake pad wear indicator
Brake disc thickness
Brake disc runout
Master cylinder I.D. 11.000 — 11.043 (0.4331 — 0.4348) 11.055 5 (0.4362)
Master piston O.D. 10.957 — 10.984 (0.4314 — 0.4324) 10.945 (0.4309)
Caliper cylinder |.D. 25.400 — 25.450 (1.0000 — 1.0020) 25.460 (1.0024)
Caliper piston O.D. 25.335 — 25.368 (0.9968 — 0.9987) 25.31 (0.996)
Specified brake fluid DOT 3 or DOT 4
Brake pad wear indicator —- To groove
Brake disc thickness 3.8 - 4.2 (0.15 - 0.17) 3.5 (0.13)
Brake disc runout —. 0.1 (0.004)
Master cylinder I.D. 12.700 — 12.743 (0.5000 — 0.5017) 12.755 (0.5022)
Master piston O.D. 12.657 — 12.684 (0.4983 — 0.4994) 12.654 (0.4978)
Caliper cylinder |.D. 32.030 — 32.080 (1.2610 — 1.2630) 32.090 (1.2634)
Caliper piston O.D. 31.948 — 31.998 (1.2578 — 1.2598) 31.94 (1.257)
14-1
BRAKE SYSTEM
TORQUE VALUES
Front brake oil bolt
Front master cylinder holder bolt
Front master cylinder cover screw
Front brake light switch screw
Brake lever pivot nut
Brake lever pivot bolt
Front brake caliper mounting bolt
Front caliper pin bolt (main)
Front caliper pin bolt (sub)
Front caliper pad pin
Front caliper pad pin plug
Rear brake reservoir tank bolt
Rear brake oil bolt
Rear master cylinder mounting bolt
Rear master cylinder push rod nut
Rear master cylinder cover screw
Rear caliper pin bolt
Rear caliper pad pin
Rear caliper pad pin plug
TOOL
Snap ring pliers
TROUBLESHOOTING
Brake lever/pedal soft or spongy
34 N-m (3.5 kgf-m, 25 Ibf-ft)
12 N-m (1.2 kgf-m, 9 Ibf-ft)
2 N-m (0.2 kgf-m, 1.4 Ibf-ft)
1 N-m (0.1 kgf-m, 0.7 Ibf-ft)
6 N-m (0.6 kgf-m, 4.3 Ibf-ft)
1.N-m (0.1 kgf-m, 0.7 Ibf-ft)
30 N-m (3.1 kgf-m, 22 Ibf-ft) ALOC bolt
18 N-m (1.8 kgf-m, 13 Ibf-ft)
23 N-m (2.3 kgf-m, 17 Ibf-ft)
18 N-m (1.8 kgf-m, 13 Ibf-ft)
2 N-m (0.2 kgf-m, 1.4 Ibf-ft)
12 N-m (1.2 kgf-m, 9 Ibf-ft)
34 N.m (3.5 kgf-m, 25 Ibf-ft)
12 N-m (1.2 kgf-m, 9 Ibf-ft)
17 N-m (1.7 kgf-m, 12 Ibf-ft)
2 N-m (0.2 kgf-m, 1.4 Ibf-ft)
17 N-m (1.7 kgf-m, 12 Ibf-ft)
17 N-m (1.7 kgf-m, 12 Ibf-ft)
2 N-m (0.2 kgf-m, 1.4 Ibf-ft)
07914 — SA50001
Brake lever/pedal hard
Air in hydraulic system
Leaking hydraulic system
Contaminated brake pads/disc
Worn caliper piston seal
Worn master cylinder piston cups
Worn brake pads/disc
Contaminated caliper
Caliper not sliding properly
Low brake fluid level
Clogged fluid passage
Warped/deformed brake disc
Sticking/worn caliper piston
Sticking/worn master cylinder piston
Contaminated master cylinder
Bent brake lever/pedal
14-2
Clogged/restricted brake system
Sticking/worn caliper piston
Caliper not sliding properly
Clogged/restricted fluid passage
Worn caliper piston seal
Sticking/worn master cylinder piston
Bent brake lever/pedal
Brake drags
Contaminated brake pads/disc
Misaligned wheel
Clogged/restricted brake hose joint
Warped/deformed brake disc
Caliper not sliding properly
Clogged/restricted brake hydraulic system
Sticking/worn caliper piston
Clogged master cylinder port
BRAKE SYSTEM
BRAKE FLUID REPLACEMENT/AIR
BLEEDING
| Ea eee eee
A contaminated brake disc or pad reduces stopping power.
Discard contaminated pads and clean a contaminated disc
with a high quality brake degreasing agent.
CAUTION:
* Do not allow foreign material to enter the system when
filling the reservoir.
* Avoid spilling fluid on painted, plastic, or rubber parts.
Place a rag over these parts whenever the system is ser-
viced.
NOTE:
* The pedal brake line air bleeding procedure is performed
in the same manner as in the lever brake line air bleed-
ing procedure.
* Once the hydraulic system has been opened, or if the
brake feels spongy, the system must be bled.
* When using a commercially available brake bleeder, fol-
low the manufacturer’s operating instructions.
BRAKE FLUID DRAINING
Make sure that the master cylinder is parallel to the ground,
before removing the reservoir cover and cap.
FRONT:
Remove the screws, reservoir cover, set plate and
diaphragm.
REAR:
Remove the reservoir tank mount bolt, screws, reservoir
cover, set plate and diaphragm.
Connect a bleed hose to the bleed valve.
Loosen the bleed valve and pump the brake lever (pedal).
Stop operating the brake when no more fluid flows out of
the bleed valve.
SCREWS COVER
SET PLATE
DIAPHRAGM BOLT
BRAKE SYSTEM
BRAKE FLUID FILLING/BLEEDING
CAUTION:
Do not mix different types of fluid since they are not com-
patible.
Fill the master cylinder with DOT 3 or DOT 4 brake fluid to
the upper level.
Connect a commercially available brake bleeder to the
bleed valve.
Pump the brake bleeder and loosen the bleed valve.
Add brake fluid when the fluid level in the reservoir is low.
NOTE:
* Check the fluid level often while bleeding the brake to
prevent air from being pumped into the system.
* When using a brake bleeding tool, follow the manufac-
turer’s operating instructions.
Repeat the above procedures until air bubbles do not
appear in the bleed tube.
NOTE:
lf air is entering the bleeder from around the bleed valve
threads, seal the threads with teflon tape.
Close the bleed valve and operate the brake lever (pedal).
If it still feels spongy, bleed the system again.
If a brake bleeder is not available, use the following proce-
dure:
Pump up the system pressure with the brake lever (pedal)
until lever (pedal) resistance is felt.
1. Pump the brake lever or pedal several times, then
squeeze the brake lever or push the brake pedal all the
way and loosen the bleed valve 1/2 turn. Wait several
seconds and close the bleed valve.
NOTE:
Do not release the brake lever or pedal until the bleed valve
has been closed.
FRONT:
UPPER LEVEL UPPER LEVEL
BRAKE BLEEDER
BLEED VALVE
14-4
BRAKE SYSTEM
2. Release the brake lever or pedal slowly until the bleed
vais hes Gace cloced: SCREWS COVER SCREWS COVER
3. Repeat steps 1 — 2 until there are no air bubbles in the
bleed hose. SET PLATE
After bleeding air completely, tighten the bleed valves to
the specified torque.
TORQUE: 2 N-m (0.2 kgf-m, 1.4 Ibf-ft)
Fill the reservoir to the casting ledge with DOT 3 or DOT 4
brake fluid to the upper level (page 14-4).
FRONT: DIAPHRAGM DIAPHRAGM
Install the diaphragm and reservoir cover.
Tighten the reservoir cover screws to the specified torque.
TORQUE; 2 N-m (0.2 kgf-m, 1.4 Ibf-ft)
REAR:
Install the diaphragm, set plate and reservoir cover.
Tighten the reservoir cover screws to the specified torque.
TORQUE: 2 N-m (0.2 kgf-m, 1.4 Ibf-ft)
Install the reservoir and tighten the mount bolt to the speci-
fied torque.
TORQUE: 12 N-m (1.2 kgf-m, 9 Ibf-ft)
BRAKE PAD/DISC 4 ° E
MOUNTING BOLTS
FRONT BRAKE PAD REPLACEMENT =a
Push the caliper pistons all the way in to allow installation
of new brake pad.
NOTE:
Check the brake fluid level in the brake master cylinder
reservoir as this operation causes the level to rise.
Remove the pad pin plugs and loosen the pad pins. PAD PIN PLUGS PAD PINS a
~ a
Remove the caliper mounting bolts and caliper.
Remove the pad pins.
Ss a
Remove the brake pads. BRAKE a.
Clean the brake caliper inside especially around the pistons.
BRAKE SYSTEM
Make sure that the pad spring is in place as shown.
Apply grease to the sliding surface of the pad pins.
Install the brake pads.
Push the brake pads against the pad spring, then install the
pad pins.
€
os BRAKE PADS -
‘ter TT ee
Push the caliper pistons all the way in to allow installation i, — ~ ee
of new brake pad. aia scons
NOTE:
Check the brake fluid level in the brake master cylinder
reservoir as this operation causes the level to rise.
Install the brake caliper to the left fork leg so the disc is
positioned between the pads.
CAUTION: MOUNTING BOLTS
Be careful not to damage the pads.
Install and tighten the new brake caliper mounting bolts.
TORQUE: 30 N-m (3.1 kgf-m, 22 Ibf-ft)
Tighten the pad pins to the specified torque.
TORQUE: 18 N-m (1.8 kgf-m, 13 Ibf-ft)
Install and tighten the pad pin plugs to the specified torque.
PAD PINS
TORQUE: 2 N-m (0.2 kgf-m, 1.4 Ibf-ft) ~
14-6
PAD PIN PLUGS §
BRAKE SYSTEM
REAR BRAKE PAD REPLACEMENT
Push the caliper pistons all the way in by pushing the
caliper body inward to allow installation of new brake pads.
NOTE:
Check the brake fluid level in the brake master cylinder
reservoir as this operation causes the level to rise.
Remove the pad pin cap and loosen the pad pin.
Remove the pad pin and brake pads.
Clean the brake caliper inside especially around the pistons.
NOTE:
Always replace the brake pads in paris to assure even disc
pressure.
Make sure the brake pad spring is in place.
Install the new brake pads.
Apply grease to the sliding surface of the pad pins.
Install the pad pin while pushing the pads against the pad
spring so that the pad ends are positioned onto the retainer
on the caliper bracket.
Install and tighten the pad pin to the specified torque.
TORQUE: 17 N-m (1.7 kgf-m, 12 Ibf-ft)
Install the pad pin cap.
BRAKE PADS
oN
14-7
BRAKE SYSTEM
BRAKE DISC INSPECTION
Visually inspect the brake disc for damage or cracks.
Measure the brake disc thickness with a micrometer.
SERVICE LIMITS: FRONT: 3.5 mm (0.13 in)
REAR: 3.5 mm (0.13 in)
Replace the brake disc if the smallest measurement is less
than the service limit.
Measure the brake disc warpage with a dial indicator.
SERVICE LIMIT: 0.1 mm (0.004 in)
Check the wheel bearings for excessive play, if the warpage
exceeds the service limit.
Replace the brake disc if the wheel bearings are normal.
FRONT MASTER CYLINDER HOSE EYELET |
REMOVAL
Drain the front hydraulic system (page 14-3).
Remove the brake hose oil bolt, searing washers and brake
hose eyelet.
CAUTION:
Avoid spilling fluid on painted, plastic, or rubber parts.
Place a rag over these parts whenever the system is ser-
viced.
WASHER
Remove the bolts from the master cylinder holder and
remove the master cylinder assembly.
BOLT/NUT
DISASSEMBLY a
Remove the pivot nut, bolt and brake lever.
LEVER
14-8
BRAKE SYSTEM
a a a
Remove the screw and front brake light switch.
SCREW SWITCH
Remove the boot.
NOTE:
Be careful not to damage the boot.
BOOT
Remove the snap ring using the special tool.
SNAP RING
TOOL:
Snap ring pliers 07914 —- SA50001
Re the s ing, washer, st ist d i
move nap ring er, master piston and spring MASTER CYLINDER PISTON
from the master cylinder.
Clean the master cylinder, reservoir and master piston in
the clean brake fluid.
NN WASHER
ee)
SPRING SNAP RING —
BRAKE SYSTEM
INSPECTION
Check the master cylinder and piston for scoring, scratches
or damage.
Measure the master cylinder I.D.
SERVICE LIMIT: 11.055 mm (0.4352 in)
Measure the master piston O.D.
SERVICE LIMIT: 10.945 mm (0.4309 in)
ce
ASSEMBLY
SCREWS 2 N-m
(0.2 kgf-m, 1.4 Ibf-ft)
SPRING
MASTER PISTON
BOOT
——_———— FRONT BRAKE LIGHT SWITCH
~*— scrEW 1 N-m (0.1 kgf-m, 0.7 Ibf-ft)
NUT 6 N-m (0.6 kgf-m, 4.3 Ibf-ft)
BOLT 1 N-m (0.1 kgf-m, 0.7 Ibf-ft)
SNAP RING
BRAKE LEVER
14-10
BRAKE SYSTEM
Coat the master piston and piston cups with clean brake
fluid.
Install the spring onto the master piston.
Install the spring and master piston into the master cylin-
der.
Install the washer and snap ring.
CAUTION:
Do not allow the piston cup lips to turn inside out.
Install the snap ring into the groove in the master cylinder,
using the special tool.
TOOL:
Snap ring pliers 07914 - SA50001
CAUTION:
Be certain the snap ring is firmly seated in the groove.
Install the boot onto the piston and into the master cylinder.
Apply silicone grease to the brake lever contacting area of
the master piston.
Install the front brake light switch onto the master cylinder
with aligning the boss of the switch and hole of the master
cylinder.
MASTER CYLINDER PISTON
a’ ed
Sy, WASHER
SPRING SNAP RING eee:
SNAP RING
14-11
BRAKE SYSTEM
a
Install and tighten the front brake light switch screw securely. SCREW SWITCH
Apply grease to the pivot bolt sliding surface.
Install the brake lever and pivot bolt.
Install and tighten the pivot nut to the specified torque.
BOLT/NUT
TORQUE:
Pivot bolt: 1 N-m (0.1 kgf-m, 0.7 Ibf-ft)
Pivot nut: 6 N-m (0.6 kgf-m, 4.3 Ibf-ft)
LEVER
INSTALLATION
HOSE EYELET
Install the master cylinder and holder.
Connect the brake hose to the master cylinder with the bolt
and new sealing washers.
Adjust the brake hose angle as shown and tighten the bolt
to the specified torque.
TORQUE: 34 N-m (3.5 kgf-m, 25 Ibf-ft)
=e
14-12
BRAKE SYSTEM
REAR MASTER CYLINDER
REMOVAL
CAUTION:
¢ Avoid spilling fluid on painted, plastic or rubber parts.
+ Place a shop towel over these parts whenever the system
is serviced.
NOTE:
* When removing the brake hose bolt, cover the end of the
hose to prevent contamination.
* Secure the hose to prevent fluid from leaking out.
Drain the hydraulic system (page 14-3).
Remove the right step bracket (page 14-24).
Remove the brake hose oil bolt, sealing washers and brake
hose eyelet.
Remove the master cylinder mount bolt and master cylinder
assembly.
Remove the reservoir tank mount bolt and reservoir tank
(page 14-3).
DISASSEMBLY
Remove the brake hose.
Remove the snap ring using the special tool.
TOOL:
Snap ring pliers 07914 — SA50001
Remove the joint pipe and O-ring
HOSE EYELET fe. ©Z MOUNT BOLTS §
SNAP RING
seaahesi?
SNAP RING PLIERS
BRAKE SYSTEM
Remove the boot.
Remove the snap ring using the special tool.
TOOL:
Snap ring pliers 07914 - SA50001
Remove the snap ring, master piston and spring from the
master cylinder.
Clean the master cylinder, reservoir and master piston in
the clean brake fluid.
INSPECTION
Check the cylinder and pistons for scoring, scratches or
other damage.
Measure the cylinder bore. I.D..
SERVICE LIMIT: 12.755 mm (0.5022 in)
Measure the piston O.D..
SERVICE LIMIT: 12.654 mm (0.4978 in)
SNAP RING PLIERS
SNAP RING BOOT
PISTON
SNAP RING
SPRING PUSH ROD
14-14
BRAKE SYSTEM
ASSEMBLY
E
<x kgf-m, 1.4 lbf-ft)
SET PLATE *
> S \
DIAPHRAGM _.§G
3
\
\ SNAP RING
\
Ff
\ O-RING
@
| SPRING
\
Q-) ®
\ MASTER PISTON
RESERVOIR TANK \
ez
PUSH ROD
aged.
Replace the boot, if damaged.
reassembly.
Coat the piston cup with the recommended brake fluid.
Install the spring onto the master piston.
Instal the spring and master piston into the master cylinder.
Apply grease to the piston contact area of the push rod.
Be certain the snap ring is firmly seated in the groove.
Snap ring pliers
Repair the piston assembly and spring as a set if dam-
Apply silicone grease to the inside of the boot.
Make sure that each part is free from dust or dirt before
ea MASTER PISTON
be.
7
\
SPRING _—Samaai PUSH ROD
Install the push rod into the master cylinder.
Install the snap ring using the special tool. SNAP RING PLIERS
07914 - SA50001
SNAP RING
14-15
BRAKE SYSTEM
Apply silicone grease to the inside of the boot.
Install the boot.
If the push rod is disassembled, adjust the push rod length
as shown.
After adjustment, tighten the lock nut to the specified 67.5 mm (2.66 in)
torque.
TORQUE: 17 N-m (1.7 kgf-m, 12 Ibf-ft)
Apply brake fluid to a new O-ring and install it onto the joint
pipe.
Install the joint pipe into the master cylinder.
Install the snap ring using the special tool.
° SNAP RING
TOOL:
Snap ring pliers 07914 —- SA50001
14-16
BRAKE SYSTEM
Install the brake hose to the master cylinder joint pipe and
reservior tank.
Install the master cylinder and tighten the master cylinder
mount bolts.
Install the brake hose eyelet joint with the oil bolt and new
sealing washers as shown.
Push the eyelet joint against the stopper, then tighten the
oil bolt the specified torque.
TORQUE: 34 N-m (3.5 kgf-m, 25 Ibf-ft)
Install the step bracket (page 14-24).
Fill the reservoir to the upper level and bleed the brake sys-
tem (page 14-3).
Install and tighten the brake reservoir mounting bolt (page
14-5).
FRONT BRAKE CALIPER
REMOVAL
CAUTION:
Avoid spilling fluid on painted, plastic, or rubber parts.
Place a rag over these parts whenever the system is ser-
viced.
Drain the brake hydraulic system (page 14-3).
Remove the brake pad (page 14-5).
Remove the bolt, sealing washers and brake hose eyelet
joints.
Remove the caliper mounting bolts and then remove the
caliper and bracket as an assembly.
JOINT PIPE BRAKE HOSE
RESERVOIR TANK
i WASHERS
see
HOSE EYELET &
BRAKE SYSTEM
DISASSEMBLY
Remove the pad spring.
PAD SPRING
Remove the caliper bracket from the caliper body.
Remove the caliper pin boot from the bracket.
Remove the bracket pin boot from the caliper body.
CALIPER BODY CALIPER PIN BOOT
BRACKET PIN BOOT BRACKET
Place a shop towel over the piston.
Position the caliper body with the pistons down and apply
small squirts of air pressure to the fluid inlet to remove the
pistons.
Mim
Do not use high pressure air or bring the nozzle too close
to the inlet.
Push the dust and piston seals in and lift them out. PISTON SEALS
CAUTION:
Be careful not to damage the piston sliding surface.
Clean the seal grooves with clean brake fluid.
14-18
BRAKE SYSTEM
INSPECTION
Check the caliper cylinder for scoring or other damage.
Measure the caliper cylinder |.D.
SERVICE LIMIT: 25.460 mm (1.0024 in)
Check the caliper pistons for scratches, scoring or other
damage.
Measure the caliper piston O.D.
SERVICE LIMIT: 25.31 mm (0.996 in)
ASSEMBLY
SHIM
oy
BRACKET
DUST SEAL
S
Sy PISTON SEAL 5)
_L6 ;
PISTON RSE m BRACKET PIN BOOT
14-19
BRAKE SYSTEM
Coat the new piston seals with clean brake fluid.
Coat the new dust seals with silicone grease.
Install the piston and dust seals into the grooves of the
caliper body.
Coat the caliper pistons with clean brake fluid and install
them into the caliper cylinder with their open ends toward
the pad.
If a caliper and bracket pin boots are hard or deteriorated,
replace them with new ones.
Install the bracket pin boot into the caliper body.
Install the caliper pin boot into the bracket.
Apply silicone grease to the caliper and bracket pins and
install the caliper bracket over the caliper body.
Install the pad spring in the caliper body.
INSTALLATION
Install the brake pads and caliper onto the left fork leg (page
14-5).
Install the brake hose eyelet to the caliper body with two
new sealing washers and oil bolt as shown.
Push the brake hose eyelet to the stopper on the caliper,
then tighten the oil bolt to the specified torque.
TORQUE: 34 N-m (3.5 kgf-m, 25 Ibf-ft)
Fill and bleed the brake hydraulic system (page 14-3).
GH DUST SEALS
“au
PISTON
CALIPER BODY CALIPER PIN BOOT
om rin
BRACKET PIN BOOT BRACKET
PAD SPRING
14-20
BRAKE SYSTEM
REAR BRAKE CALIPER
REMOVAL
Drain the brake hydraulic system (page14-3).
Remove the brake pad (page 14-5).
Remove the rear wheel (page 13-3).
Remove the caliper and bracket as an assembly.
Remove the bolt, sealing washers and brake hose eyelet
joint.
if
© BRAKE HOSE
DISASSEMBLY PAD SPRING
Remove the pad spring.
Remove the caliper bracket from the caliper body.
Remove the caliper pin boot from the bracket.
Remove the bracket pin boot from the caliper body.
CALIPER BODY CALIPER PIN BOOT
BRACKET PIN BOOT BRACKET
Place a shop towel over the piston.
Position the caliper body with the pistons down and apply
small squirts of air pressure to the fluid inlet to remove the
piston.
un
Do not use high pressure air or bring the nozzle too close
to the inlet.
14-21
BRAKE SYSTEM
Push the dust and piston seal in and lift them out. PISTON SEAL
CAUTION:
Be careful not to damage the piston sliding surface.
Clean the seal grooves with clean brake fluid.
\
f DUST SEAL
INSPECTION
Check the caliper cylinder for scoring or other damage.
Measure the caliper cylinder |.D.
SERVICE LIMIT: 32.090 mm (1.2634 in)
Check the caliper piston for scratches, scoring or other
damage.
Measure the caliper piston O.D.
SERVICE LIMIT: 31.94 mm (1.257 in)
14-22
ASSEMBLY
BRACKET
Reg PISTON SEAL
Rg BRAKE PADS
Coat the new piston seals with clean brake fluid.
Coat the new dust seals with silicone grease.
Install the piston and dust seals into the grooves of the
caliper body.
Coat the caliper pistons with clean brake fluid and install
them into the caliper cylinder with their open ends toward
the pad.
lf a caliper and bracket pin boots are hard or deteriorated,
replace them with new ones.
Install the bracket pin boot into the caliper body.
Install the caliper pin boot into the bracket.
Apply silicone grease to the caliper and bracket pins and
install the caliper bracket over the caliper body.
Rg DUST SEAL
BRAKE SYSTEM
BRACKET PIN BOOT
BLEED VALVE
PAD PIN
PISTON
CALIPER BODY CALIPERPIN | -SS6nH
\ BOOT
BRACKET PIN BOOT BRACKET
14-23
BRAKE SYSTEM
Install the pad spring in the caliper body.
PAD SPRING
INSTALLATION
Install the caliper body by aligning the boss of the
swingarm and the hole of the caliper bracket.
Install the rear wheel (page 13-9).
Install the brake pads (page 14-5).
Install the brake hose eyelet with the new sealing washers.
Aligning the brake hose eyelet between the two basses of
the caliper body.
Install and tighten the oil bolt to the specified torque.
TORQUE: 34 N-m (3.5 kgf-m, 25 Ibf-ft)
Fill and bleed the brake hydraulio system (page 14-3).
BRAKE PEDAL
REMOVAL
STEP
BRACKET
Remove the pivot cover and pivot nut (page 13-12).
Remove the bolt and step bracket.
14-24
BRAKE SYSTEM
Disconnect the rear brake master cylinder push rod from i ot EE
the brake pedal by removing the cotter pin and joint pin. RETURN SPRINGS
Disconnect the return springs from the pedal. Sm
Remove the cotter pin and brake pedal.
wy
COTTER PINS
INSTALLATION SAT
Apply grease to the brake pedal shaft and install them into . i@
the pedal pivot in the frame. :
Secure the brake pedal with the new cotter pin.
Hook the return springs to the pedal.
Connect the rear brake master cylinder push rod to the
pedal with the joint pin and secure the joint pin with a new
cotter pin.
Install the bolt and step bracket.
Tighten the bolt securely.
aq STEP
BRACKET
Install and tighten the pivot nut (page 13-16).
Install the pivot cover.
14-25
CHARGING SYSTEM/ALTERNATOR
SYSTEM DIAGRAM
REGULATOR/RECTIFIER
BATTERY
ALTERNATOR
MAIN FUSE 30A
BATTERY
Y : Yellow
G : Green
R : Red
W: White
REGULATOR/RECTIFIER
ALTERNATOR
15-0
15. CHARGING SYSTEM/ALTERNATOR
SYSTEM DIAGRAM 15-0 CHARGING SYSTEM INSPECTION 15-6
SERVICE INFORMATION 15-1 REGULATOR/RECTIFIER 15-7
TROUBLESHOOTING 15-3. ALTERNATOR 15-9
BATTERY 15-4
SERVICE INFORMATION
GENERAL
+ The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when
charging.
* The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective
clothing and a face shield.
— If electrolyte gets on your skin, flush with water.
— If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately.
¢ Electrolyte is poisonous.
— If swallowed, drink large quantities of water or milk and follow with milk of magnesia or vegetable oil and call a
physician. KEEP OUT OF REACH OF CHILDREN.
+ Always turn off the ignition switch before disconnecting any electrical components.
CAUTION:
Some electrical components may be damaged If terminals or connectors are connected or disconnect while the igni-
tion switch is ON and a current is present.
+ For extended storage, remove the battery, give it a full charge and store it ina cool, dry space. For maximum service
life, charge the stored battery every two weeks.
* For battery remaining in a stored motorcycle, disconnect the negative battery cable from the battery terminal.
* The battery can be damaged if overcharged or undercharged, or if left to discharge for long periods. These same
conditions contribute to shortening the life-span of the battery. Even under normal use, the performance of the bat-
tery deteriorates after 2-3 years.
* Battery voltage may recover after battery charging, but under a heavy load, battery voltage will drop quickly and
eventually the battery will be completely discharged. For this reason, the charging system is often suspected to be
the problem. Battery overcharge often results in problems in the battery itself, which may appear to be an over-
charge symptom.
+ Before troubleshooting the charging system, check for proper use and maintenance of the battery. Check if the bat-
tery is frequently under a heavy load, such as having the headlight and taillight ON for long periods of time without
riding the motorcycle.
+ The battery will self-discharge when the motorcycle is not use. For this reason, charge the battery every two weeks
to prevent sulfation from forming.
* When checking the charge system, always follow the steps in the troubleshooting flow chart (page 15-3).
+ Alternator servicing can be done with the engine in the frame.
15-1
CHARGING SYSTEM/ALTERNATOR
* This model comes with a maintenance free (MF) battery. Remember the following about MF batteries.
— Use only the electrolyte that comes with the battery.
— Use all of the electrolyte.
— Seal the battery properly.
— Never open the seals again.
BATTERY TESTING -
Refer to the instructions in the Operation Manual for the recommended battery tester for details about the battery test-
ing.
The recommended battery tester puts a “load” on the battery so that the actual battery condition of the load can be
measured.
Recommended battery tester BM210 or BATTERY MATE or equivalent
CAUTION:
For battery charging, do not exceed the charging current and time specified on the battery. Using excessive current or
extending the charging time may damage the battery.
SPECIFICATIONS
thes tant We ITEM SPECIFICATIONS
Battery Capacity 12 V-6Ah
Current leakage 1.0 mA max
Voltage (20°C/68°F) | Fully charged 13.0- 13.2 V
Needs charging Below 12.3 V
Charging current Normal 0.6 A/5-10h
Quick 3.0 A/1 h max
Alternator Capacity 260 W/5,000 min” (rpm)
Charging coil resistance (20°C/68°F) 0.1-0.5W
TORQUE VALUES
Flywheel nut 64 N-m (6.5 kgf-m, 47 Ibf-ft)
Stator mounting bolt
Ignition pulse generator mounting bolt
Stator/Ignition pulse generator wire clamp bolt
TOOLS
Flywheel holder
Flywheel! puller
15-2
12 N-m (1.2 kgf-m, 9 Ibf-ft)
5 N-m (0.5 kgf-m, 3.6 Ibf-ft)
5 N-m (0.5 kgf-m, 3.6 Ibf-ft)
07725 — 0040000
07KMC — HE00100
CHARGING SYSTEM/ALTERNATOR
TROUBLESHOOTING
Battery is damaged or weak
Remove the battery (page 15-4). Incorrect ——- Faulty battery
Check the battery condition using the recom-
mended battery tester.
RECOMMENDED BATTERY TESTER:
MB-210 or BATTERY MATE or equivalent
Correct
Install the battery (page 15-4).
Check the battery current leakage (Leak test:
page 15-6).
Incorrect Disconnect the regulator/rectifier 5P connec-
tor and recheck the battery current leakage.
Correct
Incorrect y
SPECIFIED CURRENT LEAKAGE: 1.0 mA max
* Faulty regulator/rectifier
Correct « Shorted wire harness
| * Faulty ignition switch
Check the alternator charging coil (page 15-8). Incorrect ——»» Faulty charging coil
STANDARD: 0.1 - 0.5 W (20°C/68°F)
Correct
Measure and record the battery voltage Correct ——»~ Faulty battery
using a digital multimeter (page 15-5).
Start the engine.
Measure the charging voltage (page 15-5).
Compare the measurements to result of the
following calculation.
MEASURED BATTERY VOLTAGE <
MEASURED CHARGING VOLTAGE < 15.5 V
Incorrect
Perform the regulator rectifier wire harness
inspection (page 15-7).
Correct
* Faulty regulator/rectifier
Incorrect ——» «+ Open circuit in related wire
¢ Loose or poor contacts of related terminal
* Shorted wire harness
Leen EEE
15-3
CHARGING SYSTEM/ALTERNATOR
BATTERY
REMOVAL
NOTE:
Always turn the ignition switch OFF before removing or
installing the battery.
Remove left side cover (page 2-2).
Remove the bolt and battery stay.
BATTERY STAY
NOTE:
Disconnect the battery negative cable first, then positive
cable from the battery.
Remoe the bolt and disconnect the battery negative terminal.
Remove the positive terminal cover.
Remove the bolt and disconnect the battery positive termi-
nal,
Remove the battery out of the battery case.
INSTALLATION "POSITIVE
Coat the battery terminal with clean grease. NEGATIVE ice genio
Place the battery into the case and connect the battery posi- TERMINAL
tive cable to the battery and install the terminal cover first
from the left side, then connect the negative cable from the
right side.
BATTERY STAY
NOTE:
Pull the cover over the positive terminal.
Install the battery stay and tighten the bolt securely.
Install the left side cover (page 2-2).
15-4
INSPECTION
Measure the battery voltage using a commercially available
digital multimeter.
VOLTAGE: Fully charged: 13.0 - 13.2 V (20°C/68°F)
Under charged: Below 12.3 V
BATTERY CHARGING
wi
* The battery gives off explosive gases; keep sparks,
flames and cigarettes away. Provide adequate ventila-
tion when charging.
* The battery contains sulfuric acid (electrolyte). Contact
with skin or eyes may cause severe burns. Wear protec-
tive clothing and a face shield.
— If electrolyte gets on your skin, flush with water.
— If electrolyte gets in your eyes, flush with water for at
least 15 minutes and call a physician immediately.
* Electrolyte is poisonous. If swallowed, drink large quan-
tities of water or milk and follow with milk of magnesia
or vegetable oil and call a physician.
* Turn power ON/OFF at the charger, not at the battery
terminals.
Remove the battery (page 15-4).
Connect the charger positive (+) cable to the battery posi-
tive (+) terminal.
Connect the charger negative (—) cable to the battery nega-
tive (-) terminal.
CHARGING CURRENT/TIME
Standard: 0.6 A/5-10h
Quick: 3.0 A/1 h max
CAUTION:
* Quick-charging should only be done in an emergency;
slow charging is preferred.
+ For battery charging, do not exceed the charging current
and time specified on the battery. Using excessive cur-
rent or extending the charging time may damage the
battery.
CHARGING SYSTEM/ALTERNATOR
BATTERY
15-5
CHARGING SYSTEM/ALTERNATOR
CHARGING SYSTEM INSPECTION
NOTE:
* Measuring circuits with a large capacity that exceeds the
capacity of the tester may cause damage to the tester.
Before starting each test, set the tester at the high capac-
ity range first, then gradually down to low capacity
ranges in order to ensure that you have the correct range
and do not damage the tester.
+ When measuring small capacity circuits, keep the igni-
tion switch off. If the switch is suddenly turned on during
a test, the tester fuse may blow.
CURRENT LEAKAGE TEST
Remove the left side cover (page 2-2).
Turn the ignition switch off, and disconnect the negtive (-)
cable from the battery.
Connect the ammeter (+) probe to the battery negative
cable and the ammeter (—) probe to the battery (—) terminal.
With the ignition switch off, check for current leakage.
NOTE:
* When measuring current using a tester, set it to a high
range, and then bring the range down to an appropriate
level. Current flow higher than the range selected may
blow out the fuse in the tester.
* While measuring current, do not turn the ignition on. A
sudden surge of current may blow out the fuse in the
tester.
SPECIFIED CURRENT LEAKAGE: 1.0 mA max
If current leakage exceeds the specified value, a shorted
circuit is likely.
Locate the short by disconnecting connections one by one
and measuring the current.
CHARGING VOLTAGE INSPECTION
Mims
If the engine must be running to do some work, make sure
the area is well-ventilated. Never run the engine in an
enclosed area. The exhaust contains poisonous carbon
monoxide gas that may cause loss of consciousness and
lead to death. Run the engine in an open area or with an
exhaust evacuation system in an enclosed area.
15-6
BATTERY NEGATIVE TERMINAL
BATTERY NEGATIVE CABLE
CHARGING SYSTEM/ALTERNATOR
NOTE:
Be sure that the battery is in good condition before per-
forming this test.
Start the engine and warm it up to the operating
temperature; stop the engine.
Connect the multimeter between the positive and negative
terminals of the battery.
CAUTION:
¢ To prevent short, make absolutely certain which are the
positive and negative terminals or cable.
* Do not disconnect the battery or any cable in the charg-
ing system without first switching off the ignition
switch. Failure to follow this precaution can damage the
tester or electrical components.
With the headlight on (Hi beam), restart the engine.
Measure the voltage on the multimeter when the engine
runs at 5,000 min” (rpm).
STANDARD:
Measured battery voltage (page 15-5) < Measured
charging voltage (see above) < 15.5 V
NOTE:
Be sure that the battery is in good condition before per-
forming this test.
REGULATOR/RECTIFIER
WIRE HARNESS INSPECTION
Remove the air cleaner housing (page 5-4).
Disconnect the regulator/rectifier 5P connector.
Check the connector for loose or corroded terminals.
BATTERY LINE
Make sure the battery voltage between Red/White (+) and
Green (-).
lf there is no voltage, measure the following:
ITEM TERMINALS SPECIFICATION
Battery Red/White (+) Battery
charging and ground (-) voltage should
line register
Green and ground Continuity exists
CHARGING SYSTEM/ALTERNATOR
CHARGING LINE
NOTE:
It is not necessary to remove the stator coil to complete this
test.
Measure the resistance between the connector terminals
and ground.
CONNECTION: Yellow and Yellow
STANDARD: 0.1-0.5 Q (20°C/68°F)
If the charging coil reading is out of specification, replace
the stator (page 15-9).
Check for continuity between the connector terminals and
ground.
There should be no continuity.
If there is continuity between the connector and ground,
replace the stator (page 15-9).
REMOVAL/INSTALLATION
Remove the air cleaner housing (page 5-4).
Disconnect the regulator/rectifier 5P connector.
Remove the bolts, and regulator/rectifier unit.
Installation is in the reverse order of removal.
NOTE:
Route the wire harness properly (page 1-25).
15-8
REGULATOR/RECTIFIER
5P CONNECTOR
Wo
ALTERNATOR
REMOVAL
- LEFT CRANKCASE COVER REMOVAL
Remove the left side cover (page 2-2).
Remove the left rear cover (page 7-3).
Remove the wire harness band.
Disconnect the alternator 3P connector and ignition pulse
generator 2P connector.
Remove the alternator and ignition pulse generator wire
from the wire band which on the main pipe.
Remove the alternator and ignition pulse generator wire
from the crip and clamp.
Remove the left crankcase cover bolts and left crankcase
cover.
Remove the gasket and dowel pins.
CHARGING SYSTEM/ALTERNATOR
gyn. ALTERNATOR
3P CONNECTOR
15-9
CHARGING SYSTEM/ALTERNATOR
* PULSE GENERATOR REMOVAL —#
GROMMET
Remove the clamp bolts and clamp.
Remove the two bolts and wire harness grommet from the
left crankcase cover.
Remove the pulse generator.
* STATOR REMOVAL
Remove the bolts and wire harness grommet.
Remove the stator.
* FLYWHEEL REMOVAL
Hold the flywheel with the flywheel holder and remove the
flywheel nut and washer.
TOOL:
Flywheel holder 07725 — 0040000
NOTE:
Be careful not to interfere the puller with the gearshift
\ WOODRUFF KEY ff
pedal. C3
SS
Remove the flywheel using the flywheel puller.
TOOL:
Flywheel puller 07KMC — HE00100
Remove the woodruff key from the crankshaft.
PULLER
15-10
INSTALLATION
+ FLYWHEEL INSTALLATION
NOTE:
When woodruff key installation, be careful not to damage
the key way groove or crankshaft.
Install the woodruff key into the crankshaft.
Clean the tapered area of the crankshaft and flywheel with a
degreasing agent and wipe them off completely.
Install the flywheel over the crankshaft by aligning its
groove with the woodruff key.
Install the washer.
Apply engine oil to the flywheel nut threads and seating
surface.
Hold the flywheel using the flywheel holder.
Tighten the flywheel nut to the specified torque.
TOOL:
Flywheel holder 07725 — 0040000
TORQUE: 64 N-m (6.5 kgf-m, 47 Ibf-ft)
CHARGING SYSTEM/ALTERNATOR
WOODRUFF KEY
CRANKSHAFT
15-11
CHARGING SYSTEM/ALTERNATOR
* STATOR INSTALLATION
Place the stator into the left crankcase cover.
Apply liquid sealant to the wire harness grommet seating
surface and install the grommet into left crankcase cover
groove.
Apply locking agent to the stator mounting bolt threads.
Route the wire harness properly and tighten the stator bolts
to the specified torque.
TORQUE: 12 N-m (1.2 kgf-m, 9 Ibf-ft)
IGNITION PULSE GENERATOR INSTALLATION
Place the ignition pulse generator into the left crankcase
cover.
Apply liquid sealant to the wire grommet seating surface and
install the grommet into the left crankcase cover groove.
Apply locking agent to the ignition pulse generator mounting
bolt threads.
Route the wire properly and tighten the pulse generator
mounting bolts to the specified torque.
TORQUE: 5 N-m (0.5 kgf-m, 3.6 Ibf-ft)
Tighten the wire cramp bolt securely.
LEFT CRANKCASE COVER INSTALLATION
NOTE:
Be careful not to damage the mating surfase.
Clean the crankcase cover mating surface.
COVER SURFACE
Install the dowel pins and a new gasket to the left
crankcase. DOWEL PINS
GASKET
15-12
CHARGING SYSTEM/ALTERNATOR
Install the left crankcase cover.
NOTE:
The left crankcase cover (stator) is magnetically attached to
the flywheel, so be careful during installation.
Install and tighten the left crankcase cover bolts securely.
Install the alternator and ignition pulse generator wire har-
ness to the clamp and crip.
NOTE:
Route the wire harness properly (page 1-22).
Install the harness to the cable clip wire harness band
which on the frame.
Lo
=
YS
“CABLE CLIP
a
Connect the alternator 3P connector and ignition pulse gen-
erator 2P connector.
Install the wire harness band.
Install the left rear cover (page 7-6).
Install the left side cover (page 2-2).
Check the engine oil level (page 3-9).
IGNITION SYSTEM
SYSTEM DIAGRAM
FRONT IGNITION COIL
SPARK PLUGS REAR IGNITION COIL
ENGINE COOLANT TEMPERATURE (ECT) SENSOR IGNITION CONTROL
MODULE
ENGINE SUB IGNITION ~=MAIN
STOP SWITCH FUSE 10A SWITCH FUSE 30A
R/BI > ~o— R
NEUTRAL
INDICATOR SUBFUSE 10A BATTERY
12V3.4W
BI/Br -O—O— R/BI 12V6AH
DIODE CLUTCH SWITCH
Lg/R GIR oT GW
— NEUTRAL GW
ident Lg SIDE STAND
— “= SWITCH
——
ENGIN COOLANT
wane Y TEMPERTURE
© (ETC) SENSOR
BI: Black
FRONT IGNITION Y : Yellow
CONTROL G : Green
MODULE R :Red
PLUGS IGNITION PULSE W: White
IGNITION
COIL
GENERATOR Lg: Light Green
— Br: Brown
O : Orange
Bu: Blue
16-0
16. IGNITION SYSTEM
SYSTEM DIAGRAM IGNITION COIL
SERVICE INFORMATION IGNITION TIMING
TROUBLESHOOTING ENGINE COOLANT TEMPERATURE
IGNITION SYSTEM INSPECTION (ECT) SENSOR
SERVICE INFORMATION
GENERAL
A WARNING
When the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an
enclosed area. The exhaust contains polsonous carbon monoxide gas that may cause loss of consciousness and lead
to death. Run the engine in an open area or with an exhaust evacuation system in an enclosed area.
CAUTION:
Some electrical components may be damaged if terminals or connectors are connected or disconnected while the igni-
tion switch is ON and current is present.
* When servicing the ignition system, always follow the steps in the troubleshooting sequence on page 16-2.
* The transistorized ignition system uses an electrically controlled ignition timing system. No adjustments can be
made to the ignition timing.
* The ignition control module (ICM) varies ignition timing according to the engine speed. The engine coolent tempera-
ture (ECT) sensor signal the ICM to compensate the ignition timing according to the coolant temperature.
* The ICM may be damaged if dropped. Also, if the connector is disconnected when current is flowing, the excessive
voltage may damage the ICM. Always turn off the ignition switch before servicing.
+ A faulty ignition system is often related to poor connections. Check those connections before proceeding.
* Make sure the battery is adequately charged. Using the starter motor with a weak battery results in a slower engine
cranking speed as well as no spark at the spark plugs.
* For ignition pulse generator removal/installation, refer to section 15.
* For spark plug inspection, see section 3.
* See section 18 for following components:
— Ignition switch
— Engine stop switch
— Neutral switch
— Side stand switch
— Clutch switch
16-1
IGNITION SYSTEM
SPECIFICATIONS
Spark plug NGK Toone car _|
ITEM SPECIFICATIONS
Standard CR8EH-9 (NGK) U24FER-9 (DENSO)
0.8 — 0.9 mm (0.031 — 0.035 in)
100 V minimum
Spark plug gap
Ignition coil primary peak voltage
Ignition pulse generator peak voltage 0.7 V minimum
Ignition timing “F” mark 12° + 1° BTDC at 1,500 + 100 min“ (rpm)
Full advance BTDC 38°
TORQUE VALUES
Engine coolant temperature (ECT) sensor 23 N-m (2.3 kgf-m, 17 Ibf-ft)
TOOL
Peak voltage adaptor 07HGJ-0020100 with commercially avallable digital multimeter
(impedance 10 MQ/DCV minimum)
TROUBLESHOOTING
Engine revolution is 7,500 rpm (min™) or less when operating the motorcycle above 5 km/h (IIG type).
Check for the speedometer operation.
— Speedometer is abnormal (see page 18-3).
— Speedometer is normal
Check for the continuity of the Black/Yellow wire between the speed sensor and ignition contro! module (ICM).
— If there is no continulty, open circult on the Black/Yellow wire.
— If there is continulty, replace the ICM.
Inspect the following before diagnosing the system.
— Faulty spark plug
— Loose spark plug cap or spark plug wire connections
— Water got into the spark plug cap (Leaking to the ignition coil secondary voltage)
lf there is no spark at either cylinders, temporarily exchange the ignition coil with the other good one and perform
the spark test. If there is as park, the exchanged ignition coil is fauitly.
“Initial voltage” of the ignition primary coil is the battery voltage with the ignition switch ON and engine stop switch
at RUN (The engine is not cranked by the starter motor).
16-2
IGNITION SYSTEM
EEE
NO SPARK AT SPARK PLUGS
UNUSUAL CONDITION PROBABLE CAUSE (Check in numerical order)
Ignition coil | Low peak voltage 1. Incorrect peak voltage adaptor connections.
primary 2. The multimeter impedance is too low; below 10 MQ/DCV.
voltage 3. Cranking speed is too low. (Battery is undercharged).
4.The sampling timing of the tester and measured pulse
were not synchronized. (System is normal if measured
voltage is over the standard voltage at least once.)
5.Poorly connected connectors or an open circuit in ignition
system.
6. Faulty side stand switch or neutral switch.
7.An open circuit or loose connection in No. 6 related circuit
wires.
* Side stand switch line: green/white wire
+ Neutral switch line: light green wire
8. Faulty ignition control module (ICM) (in case when above
No. 1 thru. 7 are normal).
No peak voltage 1. Incorrect peak voltage adaptor connections.
2. The multimeter impedance is too low; below 10 MQ2/DCV.
3. Faulty ignition switch or engine stop switch.
4. Loose or poorly connected ICM connector.
5. No voltage at the yellow/blue wire of the ICM.
6. Open circuit or poor connection in green (ground) wire of
the ICM.
7. Faulty side stand switch or neutral switch.
8. An open circuit or loose connection in No. 7 related circuit
wires.
* Side stand switch line: green/white wire
+ Neutral switch line: light green wire
9. Faulty peak voltage adaptor.
10. Faulty ignition pulse generator. (Measure peak voltage.)
11. Faulty ICM (in case when above No. 1 thru. 10 are normal).
Peak voltage is normal, but does not
spark.
1. Faulty spark plug or leaking ignition coil secondary current
ampere.
2. Faulty ignition coils.
Ignition
pulse
generator
1. The multimeter impedance is too low; below 10 MQ/DCV.
2. Cranking speed is too slow. (Battery is undercharged.)
3. The sampling timing of the tester and measured pulse
were not synchronized. (System is normal if measured
voltage is over the standard voltage at least once.)
4. Faulty ignition pulse generator (in case when above No. 1
thru. 3 are normal).
No peak voltage 1, Faulty peak voltage adaptor.
2. Faulty ignition pulse generator.
Low peak voltage
16-3
IGNITION SYSTEM
IGNITION SYSTEM INSPECTION DIGITAL MULTIMETER
NOTE:
* If there is no spark at either plug, check all connections
for loose or poor contact before measuring each peak
voltage.
* Use the recommended digital multimeter or commercial-
ly available digital multimeter with an impedance of 10
MQ/DCV minimum.
* The display value differs depending upon the internal
impedance of the multimeter.
¢ If using an Imrie diagnostic tester (model 625), follow the
manufactur’s instructions.
PEAK VOLTAGE ADAPTOR
Connect the peak voltage adapter to the digital multimeter,
or use the Imrie diagnostic tester. :
TOOLS:
Peak voltage tester or
Peak voltage adaptor 07HGJ — 0020100
With commercially available digital multimeter
(impedance 10 MQ/DCV minimum)
IGNITION PRIMARY VOLTAGE INSPECTION
NOTE:
* Check all system connections before the inspection. If
the system is disconnected, an incorrect peak voltage
will register.
*« Check cylinder compression at each cylinder and check
that the spark plugs are installed correctly in each cylin-
der.
Support the motorcycle using the side stand.
Disconnect the spark plug caps from the spark plugs on the SPARK PLUG CAP -
cylinder head.
Connect a good known spark plug to each spark plug cap
and ground the spark plugs to the cylinder as done in a
spark test.
16-4
When servicing the front ignition coil as following:
— Remove the air cleaner housing (page 5-4).
When servicing the rear ignition coil as following:
— Remove the right side cover (page 2-2).
Connect the peak voltage adaptor or peak voltage tester to
the ignition coil primary terminal.
NOTE:
Do not disconnect the ignition coil primary wires.
TOOLS:
Peak voltage taster or
Peak voltage adaptor 07HGJ -— 0020100
With commercially available digital multimeter
(impedance 10 MQ/DCV minimum)
CONNCETION:
Front ignition coil:
Blue/Yellow (+) — Body ground (-)
Rear ignition coil:
Yellow/Blue (+) — Body ground (-)
Turn the ignition switch “ON” and engine stop switch to
“RUN”.
Check for initial battery voltage.
If battery voltage is not present, follow the checks described
in the troubleshooting on page 16-3.
Shift the transmission into “neutral”.
Crank the engine with the starter motor and read each igni-
tion coil primary voltage.
PEAK VOLTAGE: 100 V minimum
Avoid touching the spark plugs and tester probes to pre-
vent electric shock.
If the peak voltage is lower than standard value, follow the
checks described in the troubleshooting on page 16-3.
NOTE:
a eee
Although measured values are different for each ignition
coil, they are normal as long as the voltage is higher than
the standard value.
If the peak voltage is lower than the standard value, follow
the checks described in the troubleshooting on page 16-3.
IGNITION COIL
(+) PROBE
IGNITION SYSTEM
PEAK VOLTAGE ADAPTER
16-5
IGNITION SYSTEM
IGNITION PULSE GENERATOR PEAK
VOLTAGE
NOTE:
Check cylinder compression at each cylinder and check that
the spark plugs are installed correctly in the cylinders.
Remove the left side cover (page 2-2).
Remove the rubber band and ignition control module (ICM)
from the battery case.
Disconnect the ICM connector.
Connect the peak voltage adaptor probes to the connector
terminals of the wire harness side.
CONNECTION:
White/Yellow terminal — Yellow terminal
Turn the ignition switch “ON” and engine stop switch to
“RUN”.
Shift the transmission into “neutral”.
Crank the engine with the starter motor and measure the
ignition pulse generator peak voltage.
PEAK VOLTAGE: 0.7 V minimum
If the peak voltage measured at ICM connector is abnormal,
measure the peak voltage at the ignition pulse generator
connector.
Disconnect the ignition pulse generator 2P connector (page
15-9) and connect the peak voltage adaptor probes to the
connector terminals of the ignition pulse generator side.
In the same manner as at the ICM connector, measure the
peak voltage and compare it to the voltage measured at the
ICM connector.
* Ifthe peak voltage measured at the ICM is abnormal and
the one measured at the ignition pulse generator is nor-
mal, the wire harness has an open or short circuit, or
loose connection.
* If both peak voltage are lower than standard value, fol-
low the checks described in the troubleshooting chart
(page 16-3).
Install the removed parts in the reverse order of removal.
ICM CONNECTOR -
16-6
IGNITION SYSTEM
IGNITION COIL SPARK PLUG CAP
REMOVAL/INSTALLATION
FRONT:
Disconnect the spark plug cap from the spark plug.
Remove the air cleaner housing (page 5-4).
Disconnect the ignition coil primary wire connectors from WASHERS IGNITION COIL
the terminals.
Remove the two bolts.
Remove the ignition coil.
Installation is in the reverse order of removal.
REAR:
Remove the right side cover (page 2-2).
- i SPARK PLUG CAP
Disconnect the spark plug cap from the spark plug.
Disconnect the ignition coil primary wire connectors from
the terminals.
Remove the two bolts, collars and nuts.
Remove the ignition coil.
Installation is in the reverse order of removal.
NOTE:
* Route the spark plug wires properly (page 1-24).
* Connect the primary wires to the original position.
Front:
Black terminal: Black/White wire
Green terminal: Blue/Yellow wire
Rear:
Black terminal: Black/White wire
Green terminal: Yellow/Blue wire
IGNITION COIL CONNECTORS
16-7
IGNITION SYSTEM
IGNITION TIMING V2? NEE
NOTE: , SS é
Read the instructions for timing light operating.
Warm up the engine.
Stop the engine and remove the timing hole cap.
Connect the timing light to the rear (No.1) cylinder spark
plug wire.
TIMING LIGHT
Start the engine and let it idle.
IDLE SPEED: 1,500 + 100 min” (rpm)
The timing is correct if the “F” mark aligns with the index
mark on the crankcase cover.
Stop the engine and connect the timing light to the front
(No. 2) cylinder spark plug wire.
Recheck ignition timing at the front cylinder.
Coat a new O-ring with engine oil and install it in the timing
hole cap and crankshaft hole cap groove. TIMING HOLE CAP
Install and tighten the cap after checking the ignition tim-
ing.
TORQUE: 10 N-m (1.0 kgf-m, 7 Ibé-ft)
16-8
ENGINE COOLANT TEMPERATURE (ECT)
SENSOR
INSPECTION
Disconnect the ignition control module (ICM) connector
(page 16-6).
Disconnect the ECT sensor connector.
Check for continuity between the ECT sensor connector and
ICM connector.
There should be continuity between the same color wires,
and no continuity between different color wires.
Drain the coolant (page 6-5).
Remove the ECT sensor from the rear cylinder.
Suspend the sensor in cold water. Heat the water slowly,
using an electric heating element.
Keep all flammable materials away from the electric heat-
ing element. Wear protective clothing, insulated gloves
and eye protection.
Measure the resistance between the sensor terminals.
STANDARD: 2 - 3 kQ at 20°C (68°F)
200 - 400 © at 80°C (178'F)
If the resistance is out of above ranges, raplace the ECT
sensor.
Install the ECT sensor with a new sealing washer and tight-
en it.
TORQUE: 23 N-m (2.3 kgf-m, 17 Ibf-ft)
Install the removed parts in the reverse order of removal.
Fill and bleed the cooling system (page 6-5).
=e
IGNITION SYSTEM
ECT SENSOR
ECT SENSOR
ECT SENSOR
16-9
ELECTRIC STARTER/STARTER CLUTCH
‘ S STARTER MOTOR STARTER RELAY SWITCH
ad
SYSTEM DIAGRAM
FUSE BOX
STARTER
RELAY SWITCH BATTERY 12V6AH
IGNITION
CONTROL
MODULS
SIDE
STAND
SWITCH
a G/R
CLUTCH SWITCH
G/wW
NEUTRAL
INDICATOR
iS 12V3.4W
SUB FUSE DIODE
10A @
BI/Br Lg/R NEUTRAL
SWITCH
R/BI STARTER Lg
SWITCH BI: Black
Y : Yellow
G: Green
R : Red
Ww
g
Bl
IGNITION SUBFUSE
SWITCH 10A
: White
Lg: Light Green
Br: Brown
17-0
17. ELECTRIC STARTER/STARTER CLUTCH
SYSTEM DIAGRAM PRIMARY DRIVE GEAR/STARTER
SERVICE INFORMATION CLUTCH
nest SSRIS STARTER RELAY SWITCH
STARTER MOTOR CLUTCH DIODE
SERVICE INFORMATION
GENERAL
i
Always turn the ignition switch OFF before servicing the starter motor. The motor could suddenly start, causing seri-
ous injury.
* The starter motor can be serviced with the engine in the frame.
* When checking the starter system, always follow the steps in the troubleshooting flow chart (page 17-2).
* A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current.
+ [If the current is kept flowing through the starter motor to turn it the engine is not cranking over, the starter motor
may be damaged.
* See page 17-11 for starter clutch servicing.
¢ See section 18 for following components:
— Ignition switch
— Engine stop switch
— Starter switch
— Neutral switch
— Side stand switch
— Clutch switch
SPECIFICATIONS
Unit: mm (in)
ee
TORQUE VALUES
Starter motor terminal nut 12 N-m (1.2 kgf-m, 9 Ibf-ft)
Starter motor front cover bolt 5 N-m (0.5 kgf-m, 3.6 Ibf-ft)
Primary drive gear lock nut 88 N-m (9.0 kgf-m, 65 Ibf-ft) Left hand threads.
TOOL
Gear holder 07724 — 0010200
17-1
ELECTRIC STARTER/STARTER CLUTCH
TROUBLESHOOTING
* Check for the following before troubleshooting the system.
— Blown main fuse (30 A) or sub-fuse (10 A).
— Loose battery and starter motor cable.
— Discharged battery.
* The starter motor should turn when the transmission is in neutral.
* The starter motor should turn when transmission is in any gear as indicated the chart below.
Side Stand Clutch Lever Starter Motor
Any Gear Up Pulled In Turn
Released Does not turn
Down Pulled In Does not turn
Released Does not turn
Starter motor will not turn
Abnormal ——» + Poorly connected battery terminals
* Open or short circuit in battery cable
Check for loose or poorly connected battery
terminals, and opened or shorted battery
cable.
Normal
Check for loose or poorly connected starter Abnormal ——*® + Poorly connected terminals or 4P connector
relay switch terminals and 4P connector.
Normal
Abnormal ——® »* Poorly connected motor cable
* Open circuit in motor cable
Check for loose or poorly connected starter
motor cable, or opened cable.
Normal
With the ignition switch ON, push the starter Clicks
switch and check for a “Click” sound from
the starter relay switch.
Connect the starter motor terminal directly
to the battery positive terminal (because a
large amount of current flows, do not use
thin wires).
Starter motor turns Starter motor
does not turn
* Faulty starter motor
No click
+ Loose or disconnected starter motor
cable
* Faulty starter relay switch
17-2
Continuity
relay switch 4P connector (page 17-16).
Voltage appeared
Abnormal
No continuity —>
Check the starter relay coil ground wire lines
(page 17-16).
Check the starter relay voltage at the starter No voltage ——>
Check the starter relay switch operation
(page 17-16).
ELECTRIC STARTER/STARTER CLUTCH
TE
Normal ——» °*
os ns
The starter motor turns when the transmission is in neutral, but does not turn with the transmission in any position
except neutral. The side stand is up and the clutch lever is pulled in.
Check the clutch switch operation (page 18-11).
Normal
Normal
Check the side stand switch (page 18-15).
Abnormal ——> +
Abnormal ——> *
= OE ns
Starter motor turns slowly
¢ Poorly connected battery terminal cable
* Poorly connected starter motor cable
* Faulty starter motor
« Worn or damaged starter motor brush
Starter motor turns, but engine does not turn
« Starter motor is running backwards
— Case assembled improperly
— Terminals connected improperly
* Faulty starter clutch
* Damaged reduction gear
* Damaged starter idle gear
Faulty neutral switch
Faulty clutch switch diode
Faulty side stand switch
Loose or poor contact of connector
Open circuit in wire harness
Faulty ignition switch
Faulty starter switch
Loose or poor contact of connector
Open circuit in wire harness
Loose or poor contact of the starter relay
switch 4P connector
Faulty starter relay switch
Faulty clutch switch
Faulty side stand switch
Open circuit in wire harness
Looss or poor contact of connector
Starter relay switch “clicks”, but engine does not turn over
* Crankshaft does not turn due to engine problem
* Faulty starter reduction gear
+ Faulty starter idle gear
eee
17-3
ELECTRIC STARTER/STARTER CLUTCH
STARTER MOTOR
REMOVAL
Always turn the ignition switch OFF before servicing the
starter motor. The motor could suddenly start, causing
serious injury.
Remove the terminal cover.
Remove the terminal nut and starter motor wire.
Remove the mounting bolts, starter motor cover stay and
starter motor.
Remove the O-ring from the starter motor.
DISASSEMBLY
NOTE:
Record the number and location of shims and washers for
correct assembly.
FRONT COVER
Remove the starter motor front cover bolts, front cover.
17-4
Remove the seal ring from the motor case.
Remove the lock washer.
Remove the shims.
Remove the rear cover.
Remove the seal ring from the motor case.
Remove the shims from the armature.
ELECTRIC STARTER/STARTER CLUTCH
SEAL RING
LOCK WASHER
SHIMS
REAR COVER
ELECTRIC STARTER/STARTER CLUTCH
Remove the bolt, washer and insulators.
BOLT WASHER/
“Na INSULATORS
Remove the brush holder assembly.
Remove the O-ring.
O-RING
BRUSH HOLDER
BRUSH HOLDER DISASSEMBLY
SPRINGS BRUSHES
Remove the motor brushes and brush springs.
INSPECTION ARMATURE
Inspect the commutator bars for discoloration.
Bars discolored in pairs indicate grounded armature coils,
in which case the starter motor be replaced.
17-6
ELECTRIC STARTER/STARTER CLUTCH
Check for continuity between individual commutator bars;
there should be continuity.
Also, check for continuity between individual commutator
bars and the armature shaft; there should be no continuity.
Check for continuity between the cable terminal and the
brush wire.
There should be continuity.
Check for continuity between the rear cover and the brush
wire.
There should be no continuity.
Disassemble the rear cover.
Inspect the brushes for damage and measure the brush length.
SERVICE LIMIT: 3.5 mm (0.14 in)
Check the bush of the rear cover for wear or damage.
BUSH
ELECTRIC STARTER/STARTER CLUTCH
Check the needle bearing of the front cover for smooth
rotation.
Check the dust seal for wear or damage.
DUST SEAL
NEEDLE BEARING
ASSEMBLY
REAR COVER
BUSH
SHIMS
BRUSH HOLDER
SPRING
SEAL RING
ARMATURE
NUTS WASHER
O-RING
INSULATORS LOCK WASHER Poa
DUST SEAL
NEEDLE BEARING
=e
SEAL RING
FRONT COVER) O-RING B
Install the springs to the holders.
Install the brushes in the brush holders. SPRINGS HOLDERS BRUSHES
17-8
ELECTRIC STARTER/STARTER CLUTCH
Install the O-ring to the terminal bolt.
Install the brush holder assembly to the rear cover, aligning
the tab of the holder with the groove of the rear cover.
O-RING
REAR COVER
Install the insulators, washer, nut to the terminal bolt in the
correct positions as recorded. INSULATORS
NUT
fo}
°°.
_7Se@
WASHER
Install the shims to the armature. ns
Install the armature into the motor case. :
Install the seal ring on the motor case.
Assemble the motor case and rear cover, aligning the index
marks.
REAR COVER
SEAL RING
= MOTOR
.— CASE
NOTE: i.
Hold the armature coil shaft, or armature might be drawn SHIMS
out by the magnetic field.
Apply grease to the dust seal of the front cover.
Install the lock washer to the cover, shims to the shaft in the
correct positions as recorded, and seal ring to the case.
LOCK WASHER FRONT COVER
y
14
SHIMS ——SGMEH DUST SEAL
17-9
ELECTRIC STARTER/STARTER CLUTCH
Install the seal ring to the motor case.
Assemble the motor case and front cover, aligning the
index marks.
Install the O-ring to the starter motor front cover bolts.
Tighten the bolts to the specified torque.
TORQUE: 5 N-m (0.5 kgf-m, 3.6 Ibf-ft)
INSTALLATION
Coat a new O-ring with engine oil and install it into the
starter motor groove.
Install the starter motor into the crankcase.
Tighten the mounting bolts to the specified torque.
Connect the starter motor wire.
Install and tighten the terminal nut to the specified torque.
TORQUE:
STARTER MOTOR TERMINAL NUT:
12 N-m (1.2 kgf-m, 9 Ibf-ft)
Install the rubber cover securely.
17-10
O-RING
BOLT
STARTER MOTOR
BOLTS
WIRE
ELECTRIC STARTER/STARTER CLUTCH
PRIMARY DRIVE GEAR/STARTER CLUTCH
REMOVAL
Remove the right crankcase cover (page 6-13).
Remove the starter idle gear and shaft.
Remove the starter reduction gear and shaft.
Remove the clutch (page 8-4).
CAUTION:
The primary gear nut has left hand threads.
Temporarily install the clutch outer.
Hold the primary drive gear using the gear holder and
remove the primary drive gear nut.
TOOL:
Gear holder 07724 - 0010200
Remove the clutch outer.
Remove the washer and primary drive gear.
| Fees —_ iil Bary
Remove the woodruff key from the crankshaft. pele Gabe ici el j
it
Remove the starter clutch. i i
’ STARTER CLUTCH "ig
ELECTRIC STARTER/STARTER CLUTCH
STARTER CLUTCH OUTER
Check the starter clutch outer for abnormal wear, or damage.
Measure the starter clutch outer I.D.
SERVICE LIMIT: 62.33 mm (2.454 in)
ONE-WAY CLUTCH
Check the one-way clutch sprag for abnormal wear, damage
or irregular movement.
ASSEMBLY
STARTER CLUTCH GEAR
NEEDLE BEARING
STARTER CLUTCH OUTER
ONE-WAY CLUTCH
SNAP RING
17-12
ELECTRIC STARTER/STARTER CLUTCH
Check that the starter clutch gear turns counterclockwise
smoothly and does not turn clockwise.
STARTER CLUTCH DISASSEMBLY STARTER
: wae CLUTCH GEAR
Remove the starter clutch gear while turning it counter- SS
clockwise
Remove the needle bearing. SNAP RINGS
Remove the two snap rings.
Remove the one-way clutch from the starter clutch outer.
NOTE:
Do not remove the one-way clutch from the clutch outer
unless it is necessary to replace with new one.
ONE-WAY CLUTCH NEEDLE BEARING
INSPECTION
STARTER CLUTCH GEAR
Check the starter clutch gear.
Measure the starter clutch gear O.D.
SERVICE LIMIT: 45.64 mm (1.797 in)
17-13
ELECTRIC STARTER/STARTER CLUTCH
Install the one-way clutch to the starter clutch outer,
Apply engine oil to the needle bearing and install it to the
starter clutch outer.
Install the two snap rings.
Install the starter clutch gear to the starter clutch outer
while turning the gear counterclockwise.
Make sure that the starter clutch gear turns counterclock-
wise smoothly and does not turn clockwise.
INSTALLATION
Install the starter clutch aligning its groove with the tooth
on the crankshaft.
Install the woodruff key to the key groove of the main shaft.
Install the primary drive gear aligning the key groove of the
primary drive gear with the woodruff key on the mainshaft.
SNAP RINGS
ONE-WAY CLUTCH 2 NEEDLE BEARING
i
anise
UTCH
17-14
ELECTRIC STARTER/STARTER CLUTCH
Install the washer.
Apply the engine oil to the threads and seating surface of a
primary drive gear nut.
GEAR HOLDER
Temporarily install the clutch outer.
Hold the primary drive gear using a gear holder and tighten
the nut to the specified torque.
TOOL:
Gear holder 07724 — 0010200
TORQUE: 88 N-m (9.0 kgf-m, 65 Ibf-ft)
Install the clutch (page 8-8).
Check the starter reduction gear, shaft and journal for wear
or damage.
NOTE:
The primary drive gear nut has left hand threads.
REDUCTION GEAR
Check the starter idle gear, shaft and journal for wear or
damage.
IDLE GEAR
Apply engine oil to the starter reduction gear, starter idle
gear and shafts.
Install the starter reduction gear, starter idle gear and shafts
to the right crankcase.
Install the right crankcase cover (page 6-18).
17-15
ELECTRIC STARTER/STARTER CLUTCH
REMOVAL/INSTALLATION
Remove the right side cover (page 2-2).
Disconnect the starter relay 4P connector.
Remove the starter relay switch, from the battery case.
Turn over the rubber cover and remove the socket bolts
and cables,
Installation is in the reverse order of removal.
INSPECTION
NOTE:
Before checking the starter relay switch, check for battery
condition.
Remove the right side cover (page 2-2).
Shift the transmission into neutral.
Turn the ignition switch ON and engine stop switch to RUN.
Depress the starter switch button.
The coil is normal if the starter relay switch clicks.
If you don’t hear the switch “CLICK”, inspect the relay switch
using the procedure below.
GROUND LINE
Disconnect the starter relay switch 4P connector.
Check for continuity between the Green/Red wire (ground line)
and ground.
If there is continuity when the transmission is in neutral or
when the clutch is disengaged and the side stand switch is
up, the ground circuit is normal (In neutral, there is a slight
resistance due to the diode).
STARTER RELAY VOLTAGE
Connect the starter relay switch 4P connector.
Shift the transmission into neutral.
Measure the voltage between the Yellow/Red (+) wire and
ground at the starter relay switch 4P connector.
If the battery voltage appears only when the starter swtich is
pressed with the ignition switch ON, it is normal.
17-16
Ss
~=
TARTER RELAY SWITCH
ELECTRIC STARTER/STARTER CLUTCH
CLUTCH DIODE
INSPECTION
Remove the right side cover (page 2-2).
Open the fuse box and remove the diode.
Check for continuity between the diode terminals.
When there is continuity, a small resistance value will register. DIODE
If there is continuity in one direction, the diode is normal. \
G/R Lg/R
Lg
17-17
LIGHTS/METERS/SWITCHES
SYSTEM DIAGRAM
FRONT BRAKE LIGHT SWITCH
N ITCH
CLUTCH SWITCH i aches
THERMO SWITCH
FAN MOTOR
SWITCH
TURN SIGNAL
RELAY
NEUTRAL SWITCH REAR BRAKE LIGHT SWITCH
SPEED SENSOR SIDE STAND SWITCH
(IG TYPE ONLY)
18-0
18. LIGHTS/METERS/SWITCHES
SYSTEM DIAGRAM CLUTCH SWITCH
SERVICE INFORMATION NEUTRAL SWITCH
TROUBLESHOOTING HORN
BULB REPLACEMENT FAN MOTOR SWITCH
COMBINATION METER COOLANT TEMPERATURE
SPEED SENSOR INDICATOR THERMO SWITCH
<kPHORIETER TURN SIGNAL RELAY
sevasi rapieiieaviee tis SIDE STAND SWITCH
HANDLEBAR SWITCHES SPEED SENSOR
(iG TYPE ONLY)
BRAKE LIGHT SWITCH
SERVICE INFORMATION
GENERAL
A WARNING
* A halogen headlight bulb becomes very hot while the headlight is ON, and remain hot for a while after it is turned
OFF. Be sure to let it cool down before servicing.
+ Use an electric heating element to heat the water/coolant mixture for the fan motor switch inspection. Keep all
flammable materials away from the electric heating element. Wear protective clothing, insulated gloves and eye
protection.
* Note the following when replacing the halogen headlight bulb.
— Wear clean gloves while replacing the bulb. Do not put finger prints on the headlight bulb, as they may create hot
spots on the bulb and cause is to fail.
— If you touch the bulb with your bare hands, clean it with a cloth moistened with alcohol to prevent its early failure.
— Be sure to install the dust cover after replacing the bulb.
* Check the battery condition before performing any inspection that requires proper battery voltage.
* Acontinuity test can be made with the switches installed on the motorcycle.
* The following color codes are used throughout this section.
Bu = Blue G = Green Lg = Light Green R = Red
BI = Black Gr = Gray O = Orange W = White
Br = Brown Lb = Light Blue P = Pink Y = Yellow
18-1
LIGHTS/METERS/SWITCHES
SSS aT
SPECIFICATIONS
Fuse
Thermo
switch
Front turn signal light
Rear turn signal light
Instrument light
Turn signal indicator
High beam indicator
Neutral indicator
Temp indicator
Main fuse
Sub fuse 10Ax5
OFF > ON 112 — 118°C (234 — 444°F)
Below 108°C (226°F)
ON — OFF
TORQUE VALUES
Neutral switch 12 N-m (1.2 kgf-m, 9 Ibf-ft)
Neutral switch terminal nut 2 N-m (0.2 kgf-m, 1.4 Ibf-ft)
Thermo switch 18 N-m (1.8 kgf-m, 13 Ibf-ft)
Side stand pivot bolt 10 N-m (1.0 kgf-m, 7 Ibf-ft)
Side stand lock nut 29 N-m (3.0 kgf-m, 22 Ibf-ft)
Side stand swich bolt 10 N-m (1.0 kgf-m, 7 Ibf-ft)
TROUBLE SHOOTING
COMBINATION METER
12V-10W x2
12V-10W x2
12V-17Wx3
12V-2Wx2
12V-1.2W
12V-2W
12 V-1.7 W
30A
* Before check the combination meter, make sure the battery, Sub-fuse (10 A), clock (10 A), speed meter 16P connector
are in good condition and connected securely.
* Turn the ignition switch ON and check the following:
— Speed meter indicator and tachometer indicator goes back.
— Meter display comes on.
18-2
TROUBLESHOOTING
Before combination meter inspection, make sure the following.
— Indicator bulbs not blown (Indicator bulb replacement/see page 18-4).
— Speed sensor is normal (Speed sensor inspection/see page 18-7).
— Tachometer is normal (Techometer inspection/see page 18-7).
Check the Sub-fuse (10 A) and Clock fuse (10 A) in the | Brown Fuse
fuse box.
NORMAL
Remove the combination meter connector and measure
the voltage between the black/brown connector and
green/black connector on the harness side.
Abnormal
SPECIFIED VOLTAGE: Battery voltage
NORMAL
Remove the combination meter connector and measure
the voltage between the black/blue connector and
green/black connector on the harness side.
Abnormal
SPECIFIED VOLTAGE: Battery voltage
NORMAL
ee: NO
Remove the combination meter connector and check the CONTINUITY
continuity between the green/black connector on the
harness side and ground.
NORMAL
Remove the battery positive cable and reset the combi-
nation meter. Abnormal
After about 30 seconds, connect the battery positive
cable and check the combination meter operation.
LIGHTS/METERS/SWITCHES
Replace the fuse
Open circuit in related wire
Loose or poor connection of related
terminal
Shorted wire harness
Brown Sub-fuse (10 A)
Open circuit in related wire
Loose or poor connection of related
terminal
Shorted wire harness
Brown Clock fuse (10 A)
Open circuit in related wire
Loose or poor connection of related
terminal
Shorted wire harness
Faulty combination meter
18-3
LIGHTS/METERS/SWITCHES
BULB REPLACEMENT
HEADLIGHT
A halogen headlight bulb becomes very hot while the
headlight is ON, and remain hot for a while after it is
turned OFF. Be sure to let it cool down before servicing.
Remove the combination meter (page 18-6).
Remove the dust cover.
Disconnect the headlight bulb connector.
Remove the bulb socket and bulb.
CAUTION:
Avoid touching halogen headlight bulb. Finger prints can
create hot spots that cause a bulb to break.
If you touch the bulb with your bare hands, clean it with
cloth moistened with denatured alcohol to prevent early
bulb failure.
Install a new bulb and removed parts in the reverse order of
removal.
Adjust the headlight AIM (page 3-22).
TURN SIGNAL LIGHT
Remove the screw and turn signal lens.
While pushing in, turn the bulb counterciockwise to remove
it and replace with a new one.
Installation is in the reverse order of removal.
NOTE:
When turn signal light lens installation, align the tab on the
lens with the groove on the turn signal light case.
BRAKE/TAILLIGHT
Remove the screws and brake/taillight lens.
While pushing in, turn the bulb counterclockwise to remove
it and replace with a new one.
Installation is in the reverse order of removal.
NOTE:
Seat the rubber packing properly.
se HEADLIGHT BULB
pe DUST COVER
TURN SIGNAL
LENS
BRAKE/
TAILLIGHT LENS
18-4
LIGHTS/METERS/SWITCHES
INDICATOR AND METER LIGHT
Remove the combination meter (page 18-6).
Remove the indicator and meter light bulb socket from the
combination meter.
Replace and install the bulb in the reverse order of removal.
NOTE:
When turn signal light lens installation, align the tab on the
lens with the groove on the turn signal light case.
COMBINATION METER
INSPECTION
Before combination meter inspection, make sure the follow-
ing.
— Indicator bulbs not blown
(Indicator bulb replacement/see page 18-4).
— Speed sensor is normal
(Speed sensor inspection/see page 18-7).
— Tachometer is normal
(Tachometer inspection/see page 18-7).
Check the main fuse (30 A), sub-fuse (10 A) and clock fuse
(10 A).
Remove the combination meter connector and measure the
voltage between the black/blown connector and green/black
connector on the harness side.
STANDARD: Battery voltage
Remove the combination meter connector and measure the
voltage between the black/blue connector and green/black
connector on the harness side.
STANDARD: Battery voltage
18-5
LIGHTS/METERS/SWITCHES
Remove the combination meter connector and check the
continuity between the green/black connector on the har-
ness side and ground.
STANDARD: CONTINUITY
Remove the battery positive cable and reset the combina- Bae + |
tion meter.
After few seconds, connect the battery positive cable and rv | | pa to |
check the combination meter operation.
REMOVAL/INSTALLATION
Remove the meter lid (page 2-7).
Remove the bolts and collars.
Disconnect the combination meter connector and remove
the combination meter.
Installtion is in the reverse order of removal.
16P CONNECTOR
DISASSEMBLY
LOWER COVER
Remove the four screws and lower cover.
Installation is in the reverse order of removal.
SCREWS
18-6
LIGHTS/METERS/SWITCHES
SPEED SENSOR
INSPECTION
Remove the combination meter connector (page 18-6).
Raise and support the motorcycle using safety stand or a rey! 9 i ol
a Lit | fool | | | ttt J
Measure the voltage between the Black/Yellow (+) and
Green/Brack (-) wire terminals of the wire harness side.
Slowly turn the front wheel by hand.
There should be pulse voltage.
If pulse voltage does not appear, check for open or short
circuit in the wire harness and loose connection of the
speed sensor 3P connector and combination meter connec-
tor.
3P CONNECTOR
If the connection of the connectors and wire harness are
OK.
Replace the combinetion meter.
cx
TACHOMETER DIGITAL MULTIMETER
INSPECTION
Check for loose or poor contact terminals of the combina-
tion meter connectors.
Disconnect the combination meter connector, connect the
peak voltage adaptor to the tachometer Yellow/Green ter-
minal and ground.
TOOLS: 5
Imrie diagnostic tester (model 625) or PERK VOLTAGE ADAPTOR
Peak voltage adaptor 07HGJ - 0020100
With commercially available digital multimeter
(impedance 10 MQ/DCV minimum)
CONNECTION: Yellow/Green (+) and Ground (-)
Start the engine and measure the tachometer input voltage.
PEAK VOLTAGE: 10.5 V minimum
Y/c|
If the value is normal, replace the tachometer.
If the measured value is below 10.5 V, replace the ICM.
18-7
LIGHTS/METERS/SWITCHES
If the value is 0 V, perform the following:
Remove the left side cover (page 2-2) and disconnect the 6P (NATURAL) CONNECTOR
ICM 22P connector.
Check for continuity between the tachometer connector ter-
minal and the ICM 22P connector Yellow/Green terminals.
If there is no continuity, check the wire harness for an open
circuit.
If there is continuity, replace the combination meter.
ICM MULTI-CONNECTOR
IGNITION SWITCH
INSPECTION
Remove the fuel tank (page 2-8).
Remove the front cowl (page 2-6).
Disconnect the ignition switch connectors.
CONNECTOR
Check for continuity between the ignition switch connectors
in each switch position.
Continuity should exist between the color coded wires as
follows:
DIMMER SWITCH
REMOVAL/INSTALLATION
Disconnect the ignition switch connectors.
Remove the two mounting bolts and the ignition switch.
Install the ignition switch and tighten the mounting bolts.
Install the removed parts.
HANDLEBAR SWITCHES
NOTE:
The handlebar switches removal/installation is refer to page
12-3.
Remove the front cowl (page 2-6).
Remove the fuel tank (page 2-8).
Check for continuity between the terminals.
Continuity should exist between the color code wire as
shown in each chart.
RIGHT HANDLEBAR SWITCH
Disconnect the right handlebar switch 6P connector.
ENGINE STOP SWITCH
RUN
STARTER SWITCH
CONNECTORS
RIGHT HANDLEBAR
SWITCH
LIGHTS/METERS/SWITCHES
IGNITION SWITCH
MOUNTING BOLTS
CONNECTOR
18-9
LIGHTS/METERS/SWITCHES
LEFT HANDLEBAR SWITCH
LEFT HANDLEBER CONNECTOR
Disconnect the left handlebar switch 9P connector. SWITCH
LIGHTING SWITCH
FREE
PUSH
BRAKE LIGHT SWITCH
FRONT
Disconnect the front brake light switch connectors.
There should be continuity with the brake lever applied,
and there should be no continuity with the brake lever is
released.
REAR
FRONT BRAKE LIGHT SWITCH
Remove the left side cover (page 2-2).
Disconnect the rear brake light switch 2P (Black) connector
and check for continuity between the terminals.
There should be continuity with the brake pedal applied,
and there should be no continuity with the brake pedal is
released.
BRAKE PEDAL 2P CONNECTOR
18-10
LIGHTS/METERS/SWITCHES
CLUTCH SWITCH
Disconnect the clutch switch connectors. “
CH | oe
There should be continuity with the clutch lever applied,
and there should be no continuity with the clutch lever is
released.
NEUTRAL SWITCH
Remove the left rear cover (page 7-3).
Disconnect the neutral switch wire.
Shift the transmission into neutral and check for continuity
between the Light Green wire terminal and ground.
There should be continuity with the transmission is in neu-
tral, and no continuity when the transmission is into gear.
HORN
Remove the front cowl assembly (page 2-4).
So
Disconnect the wire connectors from the horn.
WSS
a
Connect the 12 V battery to the horn terminal directly.
The horn is normal if it sounds when the 12 V battery is
connected across the horn terminals.
iWAKANNS
4
BATTERY
LIGHTS/METERS/SWITCHES
FAN MOTOR SWITCH
INSPECTION
FAN MOTOR DOES NOT STOP
Turn the ignition switch OFF, disconnect the fan motor
switch connector from the fan motor switch and turn the
ignition switch ON again.
If the fan motor does not stop, check for a shorted wire
between the fan motor and switch.
If the fan motor stops, replace the fan motor switch.
" FAN MOTOR SWITCH CONNECTOR
FAN MOTOR DOES NOT START
Before testing, warm up the engine to operating tempera-
ture.
Disconnect the connector from the fan motor switch and
ground the connector to the body with a jumper wire.
Turn the ignition switch ON and check the fan motor.
If the motor starts, check the connection at the fan motor
switch terminal. If it is normal, replace the fan motor
switch.
If the motor does not start, check for voltage between the
fan motor switch connector and ground. CONNECTOR
— Battery voltage: Faulty fan motor
—No battery voltage:
* Short or open circuit wire harness
* Blown sub-fuse
« Faulty ignition switch
* Poor connection of the connector
(between the ignition switch and fuse box)
REMOVAL/INSTALLATION FAN MOTOR SWITCH
Remove the radiator (page 6-8).
Disconnect the fan motor switch connector from the fan
motor switch.
Remove the fan motor switch and O-ring from the radiator.
Install the new O-ring.
Install and tighten the fan motor switch to the specified
torque.
18-12
LIGHTS/METERS/SWITCHES
COOLANT TEMPERATURE INDICATOR
THERMO SWITCH
SYSTEM INSPECTION
COOLANT TEMPERATURE INDINATOR
Remove the front cowl assembly (page 2-4).
Turn the ignition switch ON.
The all segments of the coolant temperature indicator
should comes on for a few seconds and it should show the
present temperature.
If the operation of the coolant temperature indicator is
abnormal, remove the left side cover (page 2-2) and discon-
nect the battery positive cable.
After few seconds, connect the battery positive cable and
inspect the operation of the coolant temperature indicator.
THE INDICATOR DOES NOT COME ON
Inspect the following:
— Meter fuse (15 A)
— Clock fuse (10 A)
— Combination meter 16P connector
— Related wire harness
If the above inspections are OK, faulty combination meter.
THE INDICATOR COME ON
Disconnect the thermo switch connector.
Short it ground using a jumper wire, then turn the ignition
switch ON.
The all segments of the coolant temperature indicator
should comes on.
lf the segments comes on, inspect the thermo switch (page
18-14).
18-13
LIGHTS/METERS/SWITCHES
THERMO SWITCH INSPECTION
* Wear insulated gloves and adequate eye protection.
* Keep flammable materials away from the electric heat-
ing element.
Drain the coolant (page 6-5).
Disconnect the thermo switch connector and remove the
thermo switch.
Suspend the thermo switch in a pan of coolant (50 — 50 mix-
ture) on an electric heating element and measure the resis-
tance through the switch as the coolant heats up.
NOTE:
* Soak the thermo switch in coolant up to its threads with
at least 40 mm (1.57 in) from the bottom of the pan to
the bottom of the switch.
* Keep the temperature constant for 3 minutes before test-
ing. A sudden change of temperature will result in incor-
rect readings. Do not let the thermometer or thermo
switch touch the pan.
STANDARD:
OFF -— ON: 112 - 118°C (234 - 444°F)
ON — OFF: Below 108°C (226°F)
Replace the thermo switch if it is out of specifications.
Apply sealant to the thermo switch threads. Do not apply
sealant to the switch head.
Install and tighten the thermo switch to the specified
torque.
TORQUE: 18 N-m (1.8 kgf-m, 13 Ibf-ft)
Connect the thermo switch connector.
Fill and bleed the cooling system (page 6-5).
18-14
CONNECTOR
ron My
THERMO SWITCH
SN
THERMO SW
| eee
LIGHTS/METERS/SWITCHES
TURN SIGNAL RELAY
INSPECTION
Check the following:
— Battery condition
— Broken indicator bulb or non-specified wattage
— Broken fuse
— Ignition switch and turn signal switch function
— Loose connectors
Remove the inner center cowl (page 2-6).
Remove the front cowl assembly (page 2-7).
If above items all normal, check the following:
Disconnect the turn signal relay connector from the relay. JUMPER WIRE
Short the Gray and Black/Brown terminals of the turn signal
relay connector with a jumper wire.
Turn the ignition switch ON and check the turn signal light
by turning the switch ON.
Light does not come on:
* Broken wire harness
TURN SIGNAL RELAY 2P CONNECTOR
Light comes on:
2P CONNECTOR
Check for continuity between the Gray terminal of the relay
connector and ground.
— Continuity
* Paulty turn signal relay
* Poor connection of the connector
— No continuity
* Broken Gray wire harness
SIDE STAND SWITCH
INSPECTION
Disconnect the side stand switch 2P (Green) connector.
18-15
LIGHTS/METERS/SWITCHES
Check for continuity between the color coded wire termi-
nals of the side stand switch connector.
Continuity should exist between the color coded wire termi-
nals as follows:
SIDE STAND SWITCH
| ereeniite
Sidestandup | ___O——
REMOVAL/INSTALLATION
Disconnect the side stand 2P (Green) connector (page 18-
15).
Remove the bolt and side stand switch.
Installation is in the reverse order of removal.
TORQUE: Side stand switch bolt
: 10 N-m (1.0 kgf-m, 7 Ibf-ft)
SPEED SENSOR (IIG TYPE ONLY)
INSPECTION
NOTE:
Check for the following before diagnosing:
— blown main fuse (30A) or sub-fuse (10A/TURN, STOP,
HORN, TAIL, METER)
— loose or corroded terminals of connectors
— discharged battery
Disconnect the speed sensor 3P connector.
Turn the ignition switch ON.
Check the voltage to between Brown/Black and Green/Black
of 3P connector main wire harness side.
If there is no battery voltage, check for the blown main fuse
and sub-fuse or loosen or corroded terminals of connectors
or discharged battery.
Check the continuity between Blue/Orange of the speed
sensor 3P connector and ignition control module 22P con-
nector.
D SWITCH 2P
CONNECTOR
SPEED SENSOR 3P
CONNECTOR
SPEED SENSOR 3P CONNECTOR
a
IGNITION CONTROL MODULE 22P CONNECTOR
18-16
19. WIRING DIAGRAM
a BLACK Br
Y YELLOW 0
& BLUE a
HORN TURN SIGNAL RELAY STARTER RELAY SwiTCH 6 ~ GREEN la
Avertisseue sonore Helais de clignotant bcp rt taten hai Ro RED °
uPt BUINKERREL AIS w WHT &
FUSE (MAIN) Bi NOR &
ateur wad, ere
: ad T Liste Y JAUNE 0
ag :
rie (KALPTSICHE RUNG) | Buu
o BATTERY
m Natterie G ~~ VERT ls
3 4 tier MOTOR BATTERIE R ~ ROUGE P
mar tear
WOTORANLASSEN BLANC. Gr
BI SCHWARZ
Y Gee 0
Be BLAU ub
G RUM lu
¥ ~ Wee
= ee | C
RIGHT REAR TURN SIGNAL LIGHT
Feu signal de virage arriére dreele
RECHTES. HINTERES BUNALICHT
(=o
ey
BRAKE AND TAILLIGHT
2207/54 ea fi seep
———a Se GREMS UND SCHLUSSLICHT
a:
|} ___¢ | 12V21/5
a aaa
i Terre (Chai
EROUNG (RAHMEN)
(GMITION COILS
La—Di}—La
a
LEFT REAR TURN SIGRAL UGHT
Few signal de virage arriére gauche
UINKES WINTERES BLINKLICHT
REAR GRAKE LIGHT Switch
Contactewr de stop de [rein arritre
MINTERER SREMSLCHTSCHAL TER
REGULATOR/ RECTIFIER
Regulates: /Rectificatenr
id
DE =
RMOSTATC SWITCH =
rme-interreptear
-AMOSCHAL TER
NEUTRAL SWITCH ALTERNATOR
Comtactear de petal mort Alteruateer
LEERLAUFSCHALTER WECHSEL STROM
LICHT MA SCHINE
(THON
rage de metre~ Avant position JGMTION CONTROL MODULE JGMITION PULSE GENERATOR f
HT MESSER @ELEUCHTUNG pean ori aa Grane Cimpains mae NESELSMACTERISLEINRONTER
TUNOSTEVEMODUL TUNDIMPULSGEBER
ENGINE COOLANT TEMPERATURE SENSOR
Captest de lemperwture de liquide de reireidusement dx meteet
MOTORKUHLMITTEL TEMPERATUR-SENSOR
3 SWITCH HORN SWITCH
¢ Cbéclsirage Boston d'avertimesr
‘TUNGSSCHAL TER HUPEMSCHAL TER
SDE STANO SWATCH
Commatalear de bequille tateraic
SEITEMSTANDEASCHALTER
0030Z- KPC -6100
-6400
UGHT BLUE
- BRUN
ORANGE
BLEU CLAIR
VERT CLAIR
ROSE
GRIS
BRAUN
ORANGE
~ HELLBLAU
HELLGRUN
ROSA
GRAU
19-1
RIGHT FRONT TURN SIGHAL LIGHT STARTER<ENGINE STOP SWITCH FRONT BRAKE LIGHT SWITCH
Feu signal de sirage avant droite
RECHIES WORDEAES SLINKLICHT Contactesr du bovtos Callamage. d'arrtt de muteur Contactear de slop de frein avant
ANLASS-MWOTORABSCHAL TER VOROERER BREMSLICHTSCHAL TER FAN MOTOR SWITCH
12V10W IGNITION SWITCH Commatairar de awier de veatilatenr
Contectewr principal GEBLASEMOTORSCHALTER
2UNOSCHAL TER
i ae
wmaw(1\_]
'
1
|
TEMP METER LIGHT '
1 Lampe de thermemetre
TEMPE RATURANZEIGENL AMPE
1
'
1
1
TACHOMETER LIGHT
D Fclairage de tachometre
OREHZAML ME SSER-BEL EUCHTUNG
SPEEDOMETER LIGHT
B tetsirage du compleur de vitesse
GESCHMINDIGKE!TSMESSER-SELEUCHTUNG
RIGHT TURN SIGMAL INDICATOR LIGHIT 1
Few sigoal de virage derecha |
RECKTES BLINKLICHT KONTROLLEUCHTE joy gyy Gu
t
NEUTRAL INDICATOR LIGHT ' ;
Tema du point mort |
LEERLAUF-KONTROLLEUCHTE 12V3.4W Gm:
HIGH BEAM INDICATOR LIGHT H
6 Femoin des fein de route 12vi.7W (67)
FEANLICHT KONTROLLELCKTE
AEET TURN SIGNAL WWOICATOR Lcet = T2V.4W Gm:
Few sigaal de sirage rauete
LINKER SLINKLICHT KONTAD. CEUCHTE
POSITION LiGHT (==
Fen de position
svawoLicrT © 2¥5W
oF
HEADUGHTS
Phare
SCHEINWERFER
12¥35/35W X2
POSITION LIGHT
Feu de positce ca—
STANDLICHT &
12v5W
ou
LEFT FRONT TURN SIGMAL LIGHT
Fee signal de rirage avant gaache
LINKER. VORDEREA BLINKL (CHT
Allumage + Demarrage
ZUNDUNG * START
oul
acne:
(
IGNITION » STARTER :
ae
TURN SIGNAL + DIMMER + LIGHTING + HORN SWITCH
Contactar de Favertimenr snore de fex de depasemest, C 10a
du reductear Cécisirage et de signal de vitage et Péclairage
SELEUCHTUNGS ABBLEND-SLINKL CHT HUPENSCHAL TER
Stop du frein arritre, arant+ Rouges Signal de virage+E
WORDERES, HINTERES BREMSLICHT* SCHLUSS « BLINK:
* WORDERES STANDLICHT
FAN MOTOR cxdck
SWITCH CONTINUITY D 10A| Motes de ventilsear E 104 (Se
a arussisans ec vous QUUTCH SwiTo GEBLASEMOTOR UHR
AMOROMUNG DER SOHAL TER Contactesr ¢embrasage
KUPPLUNGSSCHAL TER
SIDE STAND SWATCH (GMTION SwTCH ENGINE STOP SWITCH STARTER SWITCH TURN SIGNAL SWITCH
Vemmatairet de Dequille tatersie Comtacteur principal Comtactewr d'arrtt de motear Bouton de contact Contactear de clignotant
SEITENSTAMDERSCHAL TER ZUNDSCHALTER MOTORABSCHAL TER ANLASSCHALTER BLINKLICHTSCHAL TER
20. TROUBLESHOOTING
ENGINE DOES NOT START OR POOR PERFORMANCE AT HIGH
IS HARD TO START SPEED
ENGINE LACKS POWER POOR HANDLING
POOR PERFORMANCE AT LOW
AND IDLE SPEED
ENGINE DOES NOT START OR IS HARD TO START
Possible cause
1. Check the fuel flow to carburetor ————— Not reaching -———————»» Clogged fuel line and filter
| carburetor
Reaching carburetor
2. Perform a spark tests ————————————_- Weak or no spark -————> Faulty spark plug
| * Fouled spark plug
* Faulty ignition control module
Good Spark * Broken or shorted spark plug wire
* Faulty ignition switch
* Faulty ignition pulse generator
* Faulty engine stop switch
* Loose or disconnected ignition sys-
tem wires
3. Remove and inspect spark plugs —————— Wet plug —————————>*_ Flooded carburetor
| * Starting enrichment (SE) valve ON
posi.ion
Good * Throttle valve open
| + Air cleaner dirty
4. Start by following normal procedure Engine starts —————_>
| but stops
* Improper choke operation
* Carburetor incorrectly adjusted
* Intake pipe leaking
* Improper ignition timing (Faulty igni-
tion coil or ignition pulse generator)
* Fuel contaminated
Engine does not start
5. Test cylinder compression ————————— Low compression ————» Valve clearance too small 20 |
* Valve stuck open
* Worn cylinder and piston ring
* Damaged cylinder head gasket
* Seized valve
* Improper valve timing
20-1
TROUBLESHOOTING
ENGINE LACKS POWER
=
by hand
|
Wheels pins freely
Y
2. Check tire pressure
Pressure normal
3. Accelerate rapidly from low to second ——
Engine speed reduced when clutch
is released
'
4. Accelerate lightly
|
Engine speed increase
!
5. Check ignition timing
|
Correct
Y
6. Test cylinder compression
|
Normal
7. Check carburetor for clogging
|
Not clogged
8. Remove spark plugs
|
Not fouled or discolored
9. Check oil level and condition
Correct
Y
10. Remove cylinder head cover and
inspect lubrication
Valve train lubricated properly
20-2
. Raise wheel off the ground and spin
Possible cause
Wheels do not spin ——>»
freely .
Pressure low ———>-
Engine speed doesn’t ——>-»
change accordingly .
when clutch is °
released .
Engine speed does ——>->
not increase
Incorrect —————————_»> +
Incorrect —————————_> +
Clogged ———_————__>--
Fouled of —————————_>- +
discolored °
Incorrect —————————_>
Valve train not —————»-
lubricated properly .
Brake dragging
Worn or damaged wheel bearing
Faulty tire valve
Punctured tire
Clutch slipping
Worn clutch discs/plates
Warped clutch discs/plates
Weak clutch spring
Additive in engine oil
Starting enrichment (SE) valve ON
position
Clogged air cleaner
Restricted fuel flow
Clogged muffler
Faulty ignition control module
Faulty ignition pulse generator
Valve stuck open
Worn cylinder and piston rings
Leaking head gasket
Improper valve timing
Carburetor not serviced frequently
enough
Plugs not serviced frequently enough
Spark plug are the incorrect heat
range
Oil level too high
Oil level too low
Contaminated oil
Clogged oil passage
Clogged oil control orifice
TROUBLESHOOTING
| Possible cause
11. Check for engine overheating ———————— Overheating ———————> Coolant level low
| * Fan motor not working (faulty fan
Not overheating motor switch)
* Thermostat stuck close
« Excessive carbon build-up in combus-
tion chamber
* Use of poor quality fuel
* Clutch slipping
* Lean fuel mixture
* Wrong type of fuel
12. Accelerate or run at high speed ——————— Engine knocks -——————»* Worn piston and cylinder
* Wrong type of fuel
* Excessive carbon build-up in combus-
tion chamber
* Ignition timing to advanced (faulty
ignition control module)
Engine does not knock * Lean fuel mixture
POOR PERFORMANCE AT LOW AND IDLE SPEED
Possible cause
1. Check carburetor pilot screw © ——— Incorrect —————————»- > See section 5
adjustment
|
Correct
2. Check for leaking intake pipe .—————— Leaking ——————————-«_ Loose insulator clamps
Leaking * Damaged insulator
|
Not leak
3. Perform spark tests ——————————————_ Weak or intermittent ——»» Faulty carbon or wet fouled spark
| spark plug
Good spark * Faulty ignition control module
* Faulty ignition coil
¢ Broken or shorted spark plug wire
* Faulty engine stop switch
* Faulty ignition pulse generator
* Faulty ignition switch
* Loose or disconnected ignition sys-
tem wires
4. Check ignition timing ————————————-_ Incorrect —————————-+_ Improper ignition timing (faulty igni-
tion control module)
20-3
TROUBLESHOOTING
POOR PERFORMANCE AT HIGH SPEED
Possible cause
1. Disconnect fuel tube at carburetor ———— Fuel flow restricted ——»- Clogged fuel line
| + Faulty fuel valve
Fuel flows freely * Clogged fuel filter
2. Remove the carburetor and ——— _ Clogged ————————__» + Clean
check for clogging
|
Not clogged
3. Check valve timing ———————_————-_ Incorrect ———————_» > Cam sprocket not installed properly
Correct
4. Check ignition timing ———————————-_ Incorrect ————————_» Faulty ignition control module
* Faulty ignition pulse generator
Correct
5. Check valve spring ——————————_———_. Weak ——————__ >». Faulty spring
Not weak
POOR HANDLING
Possible cause
1. If steering is heavy —________________,. Steering stem adjusting nut too tight
* Damaged steering head bearings
2. If either wheel is wobbling —____________y». Excessive wheel bearing play
* Bent rim
* Improper installed wheel hub
* Swingarm pivot bearing excessively
worn
* Bent frame
3. If the motorcycle pulls to one side 9 -—-———--_-_____________ y. Faulty shock absorber
* Front and rear wheel not aligned
* Bent fork
+ Bent swingarm
* Bent axle
20-4
21. INDEX
AIR CLEANER... .-ncesonsenvassinsned asiuctbonnsisbanasassatboensessye 3-6
AIR CLEANER HOUSING ........:ccseeceseeseeceereenesreeetees 5-4
ALTERNATOR tusccdias skis seas esacanscsassqucaassatscdasacecetisisers 15-9
BATTERY issiistcaviccstssedeaticcsstimaccectacnseccrecatsssareentenas 15-4
BRAKE FRUID irisccaccrierscanzensanecantansscanasutsixtesecveiacecis 3-20
BRAKE FLUID REPLACEMENT/AIR BLEEDING.... 14-3
BRAKE LIGHT SWITCH (MAINTENANCE)............. 3-22
BRAKE. LIGHT SWITCH cc-c:cesuverccnsssecrscncnsontonsenauneny 18-10
BRAKE PAD DISG noe sossasseesnnonsseatedencnnsensdtonsensensanece 14-5
BRAKE PAD) WEAR sscscscsrsccavsose secontstentsonncintecivonvnnee> 3-20
BRAKE ‘PEDAL sisscissesscessssenctsecccvvnctestevsvecssvetoiesantesics 14-24
BRAKE SYSTEM 'aiciccscccesesssrccaccasadasstiawatianatnascdvonss 3-21
BULB REPLACEMENT cssccisscvesneuinnsencaniwesvnnvecdannsin 18-4
CABLE & HARNESS ROUTING..........cccscsseseseeseeees 1-20
CAMSHAFT INSTALLATION .........ccccccssecseseeeeseeeee 9-20
CAMSHAFT REMOVAL. .........cssssseesscssssssssnsesceteeene 9-6
CARBURETOR ASSEMBLY............::sscsscessesesseeseeee 5-11
CARBURETOR BASE ssscsccisccccissscitisinkeossbanssasscsansasaia 5-4
CARBURETOR CHORE sccsscccisiaccsa stats stssiecsvavoachsaasers 3-5
CARBURETOR COMBINATION .......:csscceecseseereereee 5-14
CARBURETOR DISASSEMBLY........cscesesesseereeeeees 5-9
CARBURETOR INSTALLATION .....:.essseseeesseeeeteees 5-16
CARBURETOR REMOVAL........::cecsssesssecsereeesrteereees 5-6
CARBURETOR SEPARATION ......ccccsssssesrsessrreresees 5-7
CARBURETOR SYNCHRONIZATION ......0cscceeereee0 3-12
CHARGING SYSTEM INSPECTION ..............::cs000 15-6
CHOKE SYS REM escavccscsstrnesestt tansensnnainasieicereacntes 5-18
CEU. CH sesvapncsaraccxssuee neo teenaninennananeionsninlennecveancenveas 8-4
CLUTCH DO DE sons cvsnsinaccisvnnsossoxnansaenaenanoasesssxaneys 17-17
CLUTCH LIFTER ARM REMOVAL/INSTALLATION... 8-3
CLUTCH SWITCH........---r--crsscsnsasecsensnenssanssnrssensonsce 18-11
CEU CH SYSTEM gscs:ccesvscs ivaachusise ace deasseety suena satges 3-23
COMBINATION METER..........:ccscccccsseseesseeeeererneee 18-5
COOLANT REPLACEMENT........:ceccceceersenseeseeseeenees 6-4
COOLANT TEMPERATURE INDICATOR
THERMOS WIECH sincccsstannsyscvs<ceracnancesesnsnacassansasosses 18-13
COOLING SYSTEM vesississessnvscsaceieaspinasinaninsnenegnsanien 3-14
CRANKCASE ASSEMBLY .........2:scsccssessssessesneeesenes 11-16
CRANKCASE BEARING REPLACEMENT .............. 11-13
CRANKCASE SEPARATION. .......cc:cccsccsecesssssseeeeees 11-3
CRANKCASE STAD BOLT INSPECTION.............+. 10-7
GRANKSHAED sis cisisacanscsncassusssctavsacirecansiveencrssveraeene 11-11
CYLINDER COMPRESSION.........sccssstesssesrseeseerreers 9-4
CYLINDER HEAD ASSEMBLY.........cccssersessssveeesssers 9-17
CYLINDER HEAD COVER INSTALLATION.........+++ 9-25
CYLINDER HEAD COVER REMOVAL .......:ssessreeres 9-5
CYLINDER HEAD DISASSEMBLY.........:cccsesceseeeeees 9-11
CYLINDER HEAD INSTALLATION. .......::csseceseeeeees 9-19
CYLINDER HEAD REMOVAL. ...........cs:sccesesseesseeeeee 9-10
CYLINDER HEAD SIDE COVER...........:.cccccesssseeeeeee 9-5
CYLINDER INSTALLATION iwc csxscissentossenssnconannesons 10-9
CYLINDER REMOVAL . sccsvcsecseccorvunosrensccvadsennssaeneones 10-3
DRIVE CHAIN, .snusccecancekannhacsanedeneintuenisioasaesdarcuserienten 3-16
DRIVE CHAIN SUIDER csccscesssoarcnesssesssnsvnenssscsesssauies 3-19
EMISSION CONTROL SYSTEMS ...........cscccesseseeeee 1-27
ENGINE IDLE SPEED jisivncaavccctecastociiesceticencaenimiacs 3-13
ENGINE COOLANT TEMPERATURE
(ECTISENSOR vcssscanccarscrseansinsanvinaancuaciseanse voesnennanennten 16-9
ENGINE-INSTALLATION....nsscscsseossnsessessossssrsnsssnsess 7-5
ENGINE OIL/OIL FILTER........cccscescssscsessetsseeeeeees 3-9
ENGINE REMOVAL..........:::cesscesssssssssessseeseseesseeeees 7-3
FANSMOTOR SWITCH scsccccc css eacia a elie icceanes 18-12
FORK tessiscnssienaccnatia tema arnetants eel 12-14
FRONT BRAKE CALIPER: cc.ccissccccccds cadet ininaicse' 14-17
FRONT COWIE cos cssccausliti cctv aateal eave acsanaes ee eta 2-6
ROI FEIN Ei sina cecensnts enseancanssnonsinnsarxentgcn robes 2-3
FRONT MASTER CYLINDER j......cscccscesseseeneeneeneneee 14-8
FTG on enciinrepnerasenonasnsnsinnennsnosananaanncasb vanes 12-9
AMOUNT os, «:nacnnestnnasdadasnaiesaaseansnasneeatouneacessen pears 3-4
USUI cacti ocassosssisatse si datannnninadbanos sndcennczessvede 2-8
GEARSHIET HINKAGE 55sec ccsatsicsseicattcanaaeaetsaace 8-10
GENERAL SARE IY. sassssssinaticinccinssansancacaawan taninaaoesstinn 1-1
AEA assis riccneesnscnenasonntveantsnsxaamnnnanarectones 12-3
HANDLEBAR SWITCHES. ..cc5, ict sacdessvesttesatesesns 18-9
EPG AI oars anneaonorsncnnednpncznnasnnentaees cyennsnteunh 3-22
TI aos inp incsrsntniornsasaeroonster ae eatees xtaatacean 18-11
IGDIERION! COIL... .a:sssnazscnsnanonustoveedaveatanoeasesarsansecast 16-7
IGNITION SIUC iasicnccincass osvens coasceaentaiancsostieensansasss 18-8
IGNITION SYSTEM INSPECTION .......0seccseecseseesees 16-4
IGNERION TIMING, issciseccaccscavecsiasnastannsseanaassaaatanss 16-8
LUBRICATION & SEAL POINTS .......ccccscesseeseseseees 1-18
LUBRICATION SYSTEM DIAGRAM ..........:::00000 4-0
MAINTENANCE SCHEDULE .........cccsecssseeseeseeseee 3-3
MODEL IDENTIFICATION..........cccsscseseeesseeesneneseees 1-3
MUEFLER/EXHAUS T PIPE 3 sicccstauscainy sshcseactsaeseuese 2-9
NEUTRAL: SWITCH science ae 18-11
NUTS, BOLTS, FASTENERS ......c.ccecsiscerescessesavecnse 3-25
OIE BUMP :ssccsusasnssesenapaaaepbananenancesnntxcancsnsesscstaep ane 4-3
PILOT SCREW ADJUSTMENT.......-..cs:cesseesseeseeeeene 5-18
PISTON INSTALLATION .......ccsssnsensrersscorssanecestnsesioe 10-8
PISTON REMOVAL .......:ssassssassnncpncttoacsstenhtanatiessborhes 10-5
PRIMARY DRIVE GEAR/STARTER CLUTCH ......... 17-11
RADIATOR COOLANT .......ccsscsssesessesesesesenecessceseess 3-13
RADIATOR COOLING FAN..........::ssscsceseessseeseseesees 6-8
RADIATOR RESERVE TANK .........ccccccceseesseeeerseeeees 6-13
REAR) BRAKE CALIPER oss ssnconsnsastdedeapcnaan tate cartasoe 14-21
REAR CARRIERS Aaien Ae eye Sen 2-3
REAR INNER FENDER/BATTERY BOX.........::00000+ 2-5
REAR MASTER CYLINDER.......cccccsscssesreseseeerereeteees 14-13
REAR WHEEL. .ccc-2ittra tht aiiecricatesancsnotecncees 13-3
REGULATOR/RECTIFIER cscs. .seosscsssssctuccsescazscdarteves 15-7
SEAT sicsisiiseciusxosatitsaunsandsbatadauanccsvestecameesstbaacasseuate 2-2
SECONDARY AIR SUPPLY SYSTEM...............:00 3-15,
5-19
SERVICE INFORMATION
. (BRAKE SYSTEM) .......00i2stvcrcetes tees sbaceasatateas 14-1
(CHARGING SYSTEM/ALTERNATOR) ....... 15-1
(CLUTCH/GEARSHIFT LINKAGE)...........00++ 8-1
(COOLING SYSTEM) cisisiscssseisct a eceatceceneates 6-1
(CRANKCASE/TRANSMISSION/
CRANKSHAF Pisces sctacstice wat oaatecesstets cu vtceacs 11-1
(CYLINDER HEAD/VALVES) ........cccsseesssesenes 9-1
(CYLINDER/PISTION) sete ceatcdsceteceh tdscans 10-1
(ELECTRIC STARTER/
STARTER: CLUTCH) aiccnciscmaiichinas 17-1
(ENGINE REMOVAL/INSTALLATION)........ 7-1
(FRAME/BODY PANELS/
EXHAUST SYSTEM): ussesssccesssenesosataserietenses 2-1
(FRONT WHEEL/SUSPENSION/
SSE UNG) vcscnnsscnceceyany snseh oundingunch snasentevineseexas 12-1
{FUEL SYSTEM D..,..nccsaseossncssinoensrncensncnsscisernis 5-1
(IGNITION SYSTEM).......ccscscsrsseeessesseneererees 16-1
INDEX
SS
(LIGHTS/METERS/SWITCHES) .............s0000 18-1
(LUBRICATION SYSTEM).......cscseseseseesesesee 4-1
(MAINTENANCE) vu... ccsseeseecsessssssesesessseeseese 3-1
(REAR WHEEL/SUSPENSION)..........::s000000 13-1
SERVICE RULES ccvvsserocescsraiverncsavassvomnesensuarresenicats 1-2
SHOCK ABSORBER wcessiscannecdtceeeersenuaciabecieaans 13-10
SIDE COVER «a csresscevciaveuretapsusraseatettut betes eee 2-2
SIDE STAND cn cnaiwnwnrinnaamenuieaceiee 3-24
SIDE STAND SWITCH wajicswsscccestcasseceusssasccecenncestens 18-15
SPARK PLUG jscsitcccacnnnmennaeoneee 3-6
SPECIFICATIONS i scsccusccssvcscis cczsvuecsaesuisccbes aemeeaes 1-4
SPEED SENSOR © cvccunssisceiveveccnswonenonsavetenne 18-7
SPEED SENSOR (IG TYPE ONLY) ......ceseeeceseeeee 18-16
STARTER) MOTOR. spcierscvreseeosensserennsusianssecottteeonaee 17-4
STARTER: RELAY SWITCH...... scscssosscsosossesessvervion tbs 17-16
STEERING HEAD BEARINGG...........cccsesssssseereoees 3-26
STEERING SIEM &.tmuncagcamnamatndieed. 12-23
SUSPENSION iessccseccassersc bias vetcaasecdtonacsecbeaiveades cates 3-24
SWINGARM ssiscscvcuvoncnstisscsineriasccinseccuacenctsibeatscstecs tate 13-12
SYSTEM DIAGRAM
(CHARGING SYSTEM/ALTERNATOR)....... 15-0
(ELECTRIC STARTER/STARTER CLUTCH)..... 17-0
(IGNITION: SYSTEM) iceencettcccscssssscpatebetscvsves 16-0
(LIGHTS/METERS/SWITCHES) ............:00000 18-0
SYSTEM FLOW PATTERN .......csssseesscescessseeseeseseeees 6-0
SYSTEM TESTING wesicescccscoesvireterestbaluelcotsantYoeccisene 6-3
TACHOMETER i sccereromasevoerersacersnvncsniannaitunedenvsnceverss 18-7
TAIL COVER/REAR FENDER ..........cscssssssssesesssesseoee 2-4
RHERMOS TAT wcncsusereeememepevan heaton 6-6
THROTTLE: OPERATION sesesoedsescccnvssaattoes re tecans 3-4
TOES 5s cacccereatterastdcdest fee ete eee terete teitaele 1-16
TORQUE VALUES ws scscosconnnsscedasvatcnecdecunsevaevestanesssses 1-13
TRANSMISSION bivcocsccestesvsacus Pentel ttecvivescieanecaeie 11-4
TROUBLESHOOTING
(BRAKE -SY STEM) isscscensseeiess Serie crvitacsacsevcess 14-2
(CHARGING SYSTEM/ALTERNATOR)....... 15-3
(CLUTCH GEARSHIFT LINKAGE)................ 8-2
(COOLING. SYSTEM)\...,.tiavis. £2, Asta 6-2
(CRANKCASE/TRANSMISSION/
CRANKSHAPT) scscccisssctscnsacienderetivaitentsatoene 11-2
(CYLINDER HEAD/VALVES) .......:.ccssesseeeees 9-3
(CYLINDER/PISTON) 3s. csnesscacvetcavsssecvendesseais 10-2
(ELECTRIC STARTER/STARTER CLUTCH)... 17-2
(FRAME/BODY PANELS/
EXHAUST SYSTEM) seoscnnctecvestsvenedevervecssstont 2-1
(FRONT WHEEL/SUSPENSION/
STEERING HARA Ae i hee aaiee 12-2
(FUEL: SYSTEM) sccccsssovsrsti ccs cucscesctsivbeteaconans 5-3
(IGNITION SYSTEM) cic siicssvsscstesesecsisnsasecceess 16-2
(LIGHTS/METERS/SWITCHES) ............0..000 18-3
(LUBRICATION SYSTEM).....ccscccssesssseesenees 4-2
(REAR WHEEL/SUSPENSION).......:::cceceeee 13-2
TURN SIGNAL-RELAY., .csscsnscastverhdecsore-stesent deta? eb 18-15
VALVE CLEARANCE cicccciscosisiectionstnsatansccdrracateess 3-8
VALVE GUIDE REPLACEMENT..........ccccccssccscoeeees 9-13
VALVE SEAT INSPECTION/REFACING........000004 9-14
WATER PUMP secesisics sssicsnncvscesceblcoventocicsevendn tactics 6-13
WHEELS TIRES osscscstl videsessasonantuavnsvtiattestonrctennees 3-26
21-2
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